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On the Led front, I am just using any old 5mm water clear blue led, 2 in series in each part at around 20mA.

I am likely to build in a 9V battery mount soon, along with some wire routing points, unfortunately that means things will keep evolving, so you print at risk, but its modular, so you can upgrade, and if you have glued, well then, your second helmet will be better again :-)