RuckaFett

If my memory serves me right, cause this was quite a few years ago now, I seated the helmet on my head and I figured out where to cut it by where I needed the face mask to sit... All head sizes are a little different (I'm about a 23 1/2" diameter), so it's really up to your discretion. I then marked the helmet, and then using a hand saw and a Dremel, I cut it off a little bit in front of that line. Just to be sure I hadn't mis-measured. I then "snuck up" on the right size for me by cutting it off a bit more as needed. After it was all assembled, I also added some minor padding on the inside to make it more comfortable, and so that it'd sit better on my head. You can use the bicycle style helmet pads (yours may have come with some), foam weather striping tape (try Lowe's o...

If my memory serves me right, cause this was quite a few years ago now, I seated the helmet on my head and I figured out where to cut it by where I needed the face mask to sit... All head sizes are a little different (I'm about a 23 1/2" diameter), so it's really up to your discretion. I then marked the helmet, and then using a hand saw and a Dremel, I cut it off a little bit in front of that line. Just to be sure I hadn't mis-measured. I then "snuck up" on the right size for me by cutting it off a bit more as needed. After it was all assembled, I also added some minor padding on the inside to make it more comfortable, and so that it'd sit better on my head. You can use the bicycle style helmet pads (yours may have come with some), foam weather striping tape (try Lowe's or Home Depot), or even an actual liner. I used the fabric mask that originally came with my suit. To really customize the fit, you could also use a heat gun to soften the plastic a bit, and then carefully (cause its both hot and fragile) mold it a bit for your head.

As head shapes and sizes vary, you'll have to judge for yourself on where to cut it. However, mine was somewhere between half way back and more towards the front. When I say "I didn't fill in the vent holes", I mean that I left them completely open. It was to allow some heat to escape, but honestly when I added the interior liner, it essentially closed them off any way.

That looks REALLY good! You should draft your own instructable on your process of creating that suit.

That's so awesome to hear! The iron on adhesive sounds like a great idea, but evidently was difficult to work with? I'd be really excited to see what you came up with on the AoU style suit!

That's great! Even more so since you added your own variations to the design. You should consider investigating both my personal Captain America Nashville Facebook page, where you can see all of my other suits, and the Build A Better Captain America Facebook page. I'm an administrator on there, and it has lots of useful information on build materials and products. All the best, and rock on in you Cap suit!

Much appreciated

ROCK ON Courtney!

Courtney,That looks GREAT! What are you putting the suit together for, an event or just for fun?All the best!RuckaFett,Tim Rucker

Hey, and thanks for reaching out! I actually have MANY suit upgrades that I haven't documented here on Instructables, but are on my facebook page, https://www.facebook.com/captainamericanashville/?ref=aymt_homepage_panel

Much appreciated