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Well I'll do my best to help, but most of your questions are basics that can be answered by some searching. Best way to assemble the helmet is zip ties and acetone. Paint the seams and let dry. Fill the bigger seams with bondo or auto body filler. Paint it with paint, pretty simple. The visor doesn't need to be vacuum formed. Just heated and bent. The visor model in the files is just for measurement. Hope that helps.