Update 2:
Woke up early to run to the hardware store. Scored a $25 dremel + 150pc accessory kit.
Stole my roommate's Dragon Age Sword/spear from PAX2010 and doubled it up as a quick stand.
Added foam to half the helmet. This can costed me $1.50 and had the same consistency as the X-30 foam from Tap Plastic's ($30). I was looking for a foam that would dry brittle, making it easier to carve. Forgot to invest in a utility knife and destroyed my only paring/fruit knife...
Need to buy spot putty/clay and more foam.
By the way, sanding sponges are $5.99 a block, so I bought the paper kind for $1.99 ea, and plan to wrap it around a foam block/dishwasher sponge. It still works and makes it easier to sand!
Update 3:
Test wear for sizing!
Covered in bondo. It was my first time using this stuff and I spilled it all over my left wrist. Going to take it to the warehouse for tons of sanding. Next would be to dremel in the details. But I'm pretty pleased with the basic shape so far.
Getting it smooth is very difficult and time consuming. Bondo Bondo, sand, bondo, sand, bondo, sand, sand sand sand sand pee, sand sand sand bondo sand. 
Lights came in, Hi-Bright from ELWIREPROS.com. One of the inverters came broken but I emailed them so hopefully it'll work out. Super fast shipping. Easy to connect and setup. Running on 9v battery.
I should be filling out all the rough kinks tomorrow. But the back and sides look decent...Update 3:
Ok. REALLY RUSHING
Ok. REALLY RUSHING
Flight is in less than 10 hours.
On top of finals.
Cut into 3 pieces. Terrifying.
