My costume is still very much WIP... I ran out of barge cement halfway through making the helmet (thanks to Kouri's Kylo post I figured out how to actually cosplay, hurray! EvilTedSmith's videos were also a big help). You can tell I was rushing due to the imperfect seams... I'll cover them up with some 1/8" or 1/4" foam later when I start detailing. I also messed up by attempting to add a layer of adhesive on top of the latex I used to coat the foam... didn't realize the glue I bought sprays like linear silly string. I tried to cover it up with a last minute Acrylic paint job but the smooth appearance was ruined by "glue bunnies" all over the mask. I think in the final version I may get more earthy tones like tan and brown for the mask to give it a more "Jedi" feel to it, but repainting will be required regardless once I smooth out the texture.
My endgame is to have an original set of Old Republic-esque Jedi armor for a Jedi with a respirator. I'm hoping the curviness of the detail lies will make it feel less inherently evil than the very angular designs of Sith respirators.