Holy CRAP was this a lot of work :) It was a great learning experience for me though! I hope that cosplayer Megan has a great time at Anime Detour 2012 and takes lots of pictures :) ...I will now attempt to explain how I did it!
Megan bought the helmet and brought it to me. I started by taking the visor off and taping up the hole!
Using the box that my wacom tablet came in and some more tape-- I shaped the ears!
I decided to spray everything with primer at this point. The helmet was made out of some weird material and I wanted to make sure everything would stick to it. I then sanded it.
I used something called "paper clay" to the cardboard ears. It took a while to dry. I sanded it when I was done!
I added Paper Clay to the parts of the helmet that needed to go away. like the dips in the chin-part and the vent on the top of the helmet.
I then sanded and sanded and added more paper clay.. and sanded... etc.. then I primed it all again! (and then sanded ;) )
Yellow coat! then sanded :P
I decided at this point to cut the holes into the back parts of the ears. I *was* just going to paint this part on.. but oh well. Now if Megan decides she wants to wear the helmet on a windy day-- the wind will go through these little exhaust holes instead of catching in the cat-ears and knocking her over :)
I added some more paper clay to the exhaust holes -- sanded-- and then painted once more.
After marking where the blue paint goes-- I applied the blue coat. (so pretty!)
I then drew out the symbol that goes on the front-- and painted it on!
I added a coat or two of clear enamel to seal everything in.I painted the sides of the visor.. added a clear coat on them.. and then had a HELLOFA time trying to get the visor onto the helmet. That part wasnt fun :P
Anyways-- I hope you enjoyed reading this HOW I DID IT :D













