Trial fit some 5mm foam padding with a bit of hack and slash while in the helmet. It's a little snug, especially on the extremes of the zygomatic bones - so now I have it all worked out in shapes I can trace it onto 2mm foam and fit that in with nicer cut edges.
Worked out a rough linear actuator for the faceplate hinges with more junk laying around in the workshop. It works good enough for the bush as they say.
Now to make a prettier, more slim-line one. I can find threads three times as aggressive and thus move the hinge a lot faster but you get the idea.
I've measured the pull on the hinges now and it's around 2.1kg. All I have to do is find a motor small enough, strong enough and fast enough to turn the chosen thread. There's a bit of physics involved trying to work out torque required and the speed needed to pull and push the nut the required travel, but I'm sure a boffin will step forward and assist where my brain chooses to exit the aircraft.
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