It really takes less than an hour to make the basic flight helmet, leaving more time to do other awesome stuff!
Here is the video I made showing haw to make the foam look like leather: http://www.youtube.com/watch?v=45Lxy_2lDw4&list=PLIbQjQ4h9ZxH-5CTIr0HZ6wlWgOiZzxWs&feature=share&index=1
See my other patterns here: https://gumroad.com/lostwaxoz
You can find my blog with my steampunk jewelry and other interesting bits here http://www.lostwaxoz.com
You can send me pics of your finished aviator hat at email@example.com