Hey everyone. I've been reading this thread for awhile, and thanks to all of your help am well on my way to my own thomas mask. The one area I am having big problems with is the chin/jaw area under the visor. I've been looking at paintball masks, but none of them really look at all like Thomas. His mask portion is just wider and smoother than anything I've found so far. Any tips?
Also, to anyone with a complete costume, are you putting anything between where the jacket ends and the helmet begins to cover up any skin? You can sort of see what I am talking about in this picture
. That might be going a tad overboard I guess.
Anyway, for those still building, I used a chrome helmet I found on ebay for the main part and a replacement snowmobile helmet lens for the visor. I used an LED belt buckle inside and clay molds plastered, epoxyed and painted for the ears (btw, chrome spraypaint is not even close to matching real chrome). Good luck all.