Check out Evil Ted Smith’s youtube channel for some great foam fabrication video tutorials. His helmet and female armor series are embedded below:
Are you plan on making helmets now?
Here a link to to a free Head Form template you can use.
If I had to pit a Batman helmet to start off with I would go with the TV 60s Batman. Because you have do put fabric over it. Here a link to that pattern.
Not quite yet. Maybe someday. Thanks for the links!