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All I had this afternoon was the phone camera so excuse the low quality of the images this time around.....
First, I had to cut a section out of the back of the helmet to allow my fat head through. I will hinge this in the centre and find some fasteners for the sides. Some guys have used powerful magnets, but I might look around for alternatives.
I spent about $5 at Bunnings hardware today to buy this soft foam rubber. Much softer than the foam mat some guys build suits from, but firm enough to support itself.
I made templates out of cardboard to fit inside the helmet in manageable sized pieces. Once I worked out the size and shape of the padding, I then traced it onto the rubber and cut it out.
I found gluing with the hot-glue was easiest to position the piece in place, then glue a small part of it, usually in the centre to hold it in place. Then it was just a matter of gluing the edges bit at a time.
I've left a little protruding past the edge of the helmet so the faceplate has an edge to seat on for a snug seal. The exposed textured rubber looks great in the cheek depressions.
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