welp, Bigbisonts awesome youtube videos have inspired me to try making this thing.
i have a piece of sheet steele scrap from home depot leftover from when i made an Ash, Evil Dead chainsaw. gonna probably need an anvil at some point but i have a vice and some beers so here I go.

Thanks to bigbisonts thread I decided to go ahead and try my hand at a new ear hinge since my old one was beyond repair. my forst attemp looked pretty nice but was too large. looked mike the hot toys figure version. Im now making a smaller one.

Making the holes in the center is by far the longest part, i drill two holes, then knock out the material in the middle with a chisel, then ise a dremel to shape them. sure wish there was a faster way.
I got a thin sheet of steele at home depot it was 1'x1' . seems like aluminum would work much better feom what ive seen, this stuff tends to want to kink but does make nice sharp lines when bending it in a vice.

So the first try was a little too big to look accurate, I recut the top part and made a new bottom piece. prett happy with it. made the trapezoid but putting it in a vice and just kinking it. making the holes is a pain in the ass.

Dont try to fit the top part to the helmet after its attached. round it extra and the rivets will pull it into shape. I kinda messed mine up by smacking it with a hammer once it was in place.

I use this to make the slots, it’s a handheld hole punch.
The good thing is that they’re quite cheap and will save you a whole lot of work.

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Cpl N.Storey A12/TQ2.0.02132E1
MARINE RAIDER

hoy lord, thanks schotti, I'm gonna get one of those!
Damn theyre only 30 bucks..

Do you make a hole on each side then cut out the middle?
Or do you just make a row of holes one by one until the slot is cleared out?

You can do it both ways, but I make a row and then just file the slot till you have a perfect shape, works just fine for me.

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Cpl N.Storey A12/TQ2.0.02132E1
MARINE RAIDER

I took a one-ear playstation 4 turtle beach headset and added it to my helmet.
Its very shite looking but it works loud and clear. very happy with how it functions.
Ill be rebuilding it and making it look cleaner. Cant wait to use this at a convention and jam to music. will also make it easier to locate friends without taking my phone out. there is a volume control and a mic on off control.

I'm open to suggestions for how to enclose the microphone tip. I might use a piece of screen door material and make a cylendar with a round end cap. Also looking for a metal pen, so I can drill a bunch of tiny holes in it or make an accurate end cap.

thats cool. I have tossed around this idea myself but never take action. A functional mic/speaker would be extremely useful.

youll want a gaming headset with volume control and a mic on/off switch. Also a large enough metal tube so you done have to cut it lengthwise like I did. Im considering rewiring this with heavier wire. Bluetooth is also an option. There are 1" bluetoth "broadcasters" on ebay for 15 bucks.

Im rolling around the idea of putting multiple speakers inside the helmet so I can walk around with a full-on rock concert inside it, all bluetooth, plus bluetooth mic. When joker gets his eyepiece finished I might take notes and put a screen in place of the IR sight. if i could walk around Con with a beer in my hand watching aliens on that little screen.... getting ahead of myself.
Anyway this thing works better then expected and takes about 1.5 hrs total.