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You could just use cardboard. I used the mache to firm up the piece and act as a better base for for filling and smoothing out the helmet. I also find it evens out irregularities.
I actually put very thin cardboard/foam over the paper mache parts. I used spot filler (a bondo product) on the brow to get it smooth. You can do this will the other parts if you don't want to use the cardboard method.
Thanks for the compliment! I get all of my foam from craft stores, specifically Michaels in Canada. If you are really stuck you can always check out TNT Costume Supply online: http://tntcosplaysupply.com/index.htmlHope this helps!
The spray paint was actually the most expensive part. I mostly used recycled cardboard.If I had to crunch the numbers I would say it didn't cost more than $50.
Homemade Wooden Watch (From Scratch)
3D printable railway rifle (fallout 3)
Bottle Rocket Lamp
Use an Xbox 360 Controller on OS X (wired + wireless)
Make a Bedroom Lamp From Shims
ShopBot: The Colletsium! A Router Bit Holder
Make a wooden pendant on a necklace
CNC Solid Wood Universal Alarm Clock Dock
Dovetailed Wooden Glasses
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Make A Chunky Wooden Ring
Leather Plague Doctor Mask