I've researched online and found out that welding helmets are primarily made of fiberglass or a poly resin mixture ... and people that have hand painted them have done it with polyurethane paint ... but that's all they say.
Wouldn't you need to clear coat the final work and if so with what? Since you'd assume he'll be working in a hot, flamable environment, the kind of paint and clear coat you use would have to be safe ...
Does anyone have any tips or suggestions on where to start on this project ... what materials to use ... and how to do it make the end product as safe as possible?
I did what I always do when I want to launch a new product line... I snooped around to first see what everyone else is doing. (Then I usually try to do even better!) Anyway, many painters are gracious enough to share their techniques, if you will just google "paint welding helmet". Many of them seem to be using primers, paints and topcoats that are made for motorcycles.
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