If you’re ready to sign up for the Rebellion, Instructables user badjer1 has a tutorial that can help you look the part of an X-wing pilot. He started the project by acquiring an actual standard flight helmet on eBay for about $50. That helmet served as the base, and badjer1 modified it using his own design inspired by those in the Star Wars films. Here’s how he prepped the helmet he found:
Strip all the parts and screws, etc. off the helmet. Set them aside so they don’t get lost. Get down to just the shell. Sand off all paint, primer, imperfections, glue residue to get down to the fiber glass. It’s unhealthy to breathe this dust so wear a dust mask.
We will use fiberglass bonding putty to contour the seams, and fill them for smooth transitions. So to ensure it will stick, sand past the primer to the raw fiberglass.
See a couple in progress photos below and get all the details and step by step images at Instructables.