Helmet replica using vacuum forming?

[aidynskas]

Hi,

I've been looking for a way to form my own custom helmet similar to this one (PASGT):
http://img.alibaba.com/photo/1131465...tic_Helmet.jpg

I've just started researching vacuum forming and already started building small vacuum forming machine to see how this whole thing really works and practice a little before making the helmet above.

Before I get even deeper into vacuum forming I have a few questions:
1. Is it possible to form the helmet replica above with home-made vacuum forming box and oven?
2. Will it be durable enough to withstand small damages (like a drop to the ground)?
3. I'm planning to use ABS sheets, since I believe they are more durable. Is it a good choice?
4. I already own Chinese replica one, any suggestions for making a mold out of it?

Any other suggestions comments are very welcome!

Thank you!

[High Seas]

AIDYNSKAS --
First welcome to the board!
Outta be very do-able. Take a quick google on TK560 Those guys do a lot of complex helmets -- star wars fans, and youd find some good tips there.
Cheers - Jim