I'm also excited about the prospect of joining the 501st with this costume. They raised 5.8 million dollars in 2011 for charity.

Pretty amazing head gear you made. How comfortable is it to wear?

it isn't comfortable yet, but I removed the stock padding in the batting helmet I used and will add more to reconfigure where my head'll sit

i.e. there is NO padding atm

Well good luck with the customizing - you're going to look awesome!