I have tweaked the mockup further and reduced the polycount to make the foldings easier and the flaps larger. So far I have built two versions in different sizes to check out which one looks better. The main problem I have is that different sources state different sizes of the real prop. Amazon says, the efx helmet is 34 x 30 x 30 cm (which can't be fully true because the width and length are not equal), the Hollywood auction catalogues say the original prop was 30 cm high. So I took a value inbetween (32 cm) and find it a good fit for an "average" head (whatever that means
). I do have a certain advantage as I have a similar statue like Dirk Benedict. We are about the same height (+ / - 1 cm), thus I assume that our heads are of similar size, too. So I'll have to compare some shots of him and me wearing the helmet to be sure.
In the meantime I give you a sneak peak at the kit. I have attached the 32 cm version of the mockup for you to check out. Feel free to toy around with it - but please keep in mind that this is a simplified version which cannot be used to produce a good-looking prop replica. The final (good) one will come with the final kit, including a proper texture and the detailing. The mockup is designed for fast and easy assembly to check out if you have to scale up or down the final plans to make your prop fit on your head.
Strangely Pepakura has produced some zig-zag lines in the unfold (I have no idea why it did that and I was unable to get rid of that). Ignore that and imagine these lines as being straight. To save ink I recommend to print the pattern in white.