Friendly neighborhood self-confessed laconophilia, whose armor suits him, but it can not hide that mark (Nothing ever will), who was prepared the very moment that he let his arrow fly, that’ll slay anything that's evil (that's his deal), who will never die (just go Missing In Action), who's desperate to regain his honor, who has the innate ability to be overlooked and ignored, who hides a bitter heart under a veneer of lovable idiot, and who knows deep down that Who I am is not who I want to be...
I've been used as the base model for 4 Marvel Sketch Cards, 1 Topps Star Wars Galaxies trading card, a Star Wars Insider cover image, and a T-Shirt at Hot Topic.
The EVA helmet is an issue I have devoted some thought to, and have seen done well once in the past, or at least, painted up well. At one point I considered doing a Meta costume myself. I like characters that don’t talk at all or, just a little. Meta, Link, Snake Eyes, Boba Fett. It’s a long story why, but suffice to say, being Caboose and being talkative is actually miles outside my comfort zone. But, it helps me.
Sorry, getting off topic.
Anyway, there are two primary approaches to visibility out of the EVA helmet.
Approach 1. I have seen some people attempt is to fabricate the visor as the make the helmet out of Pepakura. As they fiberglass and the rest of the helmet, they fiberglass the visor area as well. Then once the fiberglass is set, and smoothed out, they cut out the recessed panel areas on the visor. The rest of the visor is painted mirror gold, and then plastic tinted with mirrored gold window tinting is glued into place. It is easy to apply something like mirrored window tinting to small, relatively flat areas, as opposed to trying to apply window tinting to the complex shapes of the entire visor area. It just won’t work. So, approach one is everything on the helmet is solid fiberglass/resin except for the recess areas. The tinting will not perfectly match up the paint, but if you look at reference images of the visor, the recessed areas are a slightly different area.
The second approach is to fabricate the entire visor out of vacuum formed plastic. The visor can then be painted with mirrored airbrush painting. There was a good thread on the 405th by a costumer who built a Master Chief suit while deployed overseas, and used airbrush paints. You could still see out, but the visibility was even furthered reduced from normal tinted visors. I would link to it; unfortunately the 405th forums are a bit of a mess…to put it mildly.
Hands down, the past EVA helmet was done by thorssoli. He uses/used the second approach, to magnificent effects. It would appear that he vacuum forms his visors with a pre-tinted gold plastic with god visibility, negating the need for painting/applying a tinting. You can see it in this thread here: