There is a small gap between the visor and front. I will try the washer trick. I have also ordered a small fan. My husband has a trooper helmet so,I am learning from his too.

Haven't started the robe yet. Wanted to get the lid first, now it's time to go shopping for fabric. Thanks guys, will post swatches.

Helmet arrived a few days ago! If you all wouldn't mind taking a look and let me know how it looks and what (if anything) needs to be done in order to pass 501st approval!

Thanks!