Sorry, I've been gone so long. I'm taking a break from this build to make a costume for my wife. I did finish the stomach plate, thou. I'll take some pictures soon.
For those who are interested, here are more of the Templates I made:
http://www.4shared.com/file/103555545/4f48b35f/Chest.html
http://www.4shared.com/file/103555544/384f83c9/Neck_stomach.html
http://www.4shared.com/file/103555543/a62b166a/forearm_upper_arm.html
Thank you.
Looks pretty awesome. Thanks for ru?ning my social life even more than Fallout did.... ([/sarcasm])
As I read earlier, you mention something about turning the helmet from a "Torture Device" to something fitted. From experience I know that a used motorcycle helmet or those used in construction (safety helmets, sorry don't know the english word for it) or the helmets that Skaters use for protection.
The motorcycle and skater helmets have foam inside that is easily carved to fit inside yours. Just use a dremel to cut the outer hard plastic shell and use the foam inside the Power Armor helmet. The construction safety helmets have a plastic "crown" inside that can be fitted in the helmet, however it isn't as comfortable, or easy to fit in the helmet as the foam based helmets.
The motorcycly and skate helmets can best be acquired at yard or garagesales or any other second hand store, since firs hand ones are expensive as wel. Doesn't matter if someone even had a real accident with them since you won't be using them for protection. so second hand is best and saves you some bucks.
The constructionhelmet can be acquired at nearly every hardware store or construction site. Construction site might give you one, since there is always a worker careless enough to let it fall a few floors, get it broken somehow or whatever. They can't use it if the plastic's broken, but you can

Thanks for the templates, I'll work something out. If all else fails, its back to aluminum and my welding machine