On the right you can also see how the helmet looks once the initial cut is made for the rest for the T-visor.This is best done with the original pattern lined up and traced. Slowly scoring the plastic with a matte knife seems to be the most effective way of getting smooth, straight lines for this part.
If you remember from my vacuum form post, I mentioned that the dome form was a little too deep for the vacuum form process and caused some wrinkles that needed to be cut off and filled with Bondo. I did this by covering the outside of the holes with scotch tape and filling them from the inside with Bondo.
Having extra 5-gallon bucket pieces lying around makes a great platter for mixing and using Bondo. Because of the relatively small amount of Bondo used for each touch up on the domes, a tongue depressor was an adequate tool to apply a thin layer.
You can also see the Bondo that appears on the seems of the cheeks. While seems are close they seem to rarely match perfectly and the Bondo provides a good way to smooth those edges out. For this part I actually used my fingers, a) to limit the amount that ends up on the cheek and, b) they are about the right width to effectively cover the seam. (**Note to self and others: when using fingers with bondo, gloves are a good idea. Its hard to wash off.)
