Thanks guys!
Had a momentary panic when I realised that in printing out the templates scaled and on our crazy UK-sized A4 paper that I'd accidentally used the dome base rather than the helmet base for the shape of the bottom of the bucket. Thankfully because everything was in card, it was easy to switch in the proper helmet base - which is circular, rather than the oval/egg shape of the dome and now the form has a much better flare at the sides...
So pleased that the Foamex (Sintra) is still on its way to us - I believe in
"Measure twice, Cut once" anyway, but on this project, I think it's going to be
"Measure twice, Cut once, Build it in card first, Think about it and only then Attempt it in Sintra!"Spent rest of this Sunday afternoon testing out new tools and while we're still in discussion about the finer details of her gear, we did agree that something like a Jango-style WESTAR-34 blaster is going to be her weapon of choice, so I quickly printed an image from Google at what appeared to be the right size, slapped it on some card and cut it out to check it would fit in her hands. (I later found the WoF blaster templates :
http://www.thedentedhelmet.com/attachments/f28/jango-westar-blaster-blueprints-completed-jango-fett-blaster-rev-pdf-73057d1385267782 and discovered that my size guesstimate was pretty much exact.) Planning to cut the handle out of MDF and make the barrel and other pieces from Sintra/PVC piping.
Am also doing some prep-work on gauntlets too - figuring that between the helmets, weapons and gauntlets there's plenty to get my teeth into before we source material for flak jackets, tailor those and start on the armour itself.
Clearly the enthusiasm is building here in the household,
Jayne tweeted this pic of me getting to grips with how to set up the rotary tool I bought last week (an item I've always wanted, but until now never had a project that justified it.)
The revised bucket is in the bottom left of the image, ready and waiting to be wrapped in metres of Sintra...

Hope you've all had a great weekend!