I cast about for ideas at the Salvation Army store and this is what I came up with.
The cranium is, I think, the bowl from a small electric mixer. The chin strap isn't from a belt but from a more complicated assemblage of straps, the original purpose of which is a mystery.
Luckily I had some sort of sturdy foam stuff in the basement which was just perfect for this purpose. All metal edges are rolled including on the securing tabs, and the whole thing is held together with rivets, except for the lining, which is epoxied in.
A classmate pointed out that the visor would also be a convenient spot for a lamp. I was originally intending to reinforce the visor with steel rods, but after riveting it, decided it was stiff enough - making it completely collapse-proof would probably be more a hazard to the wearer's neck.
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