Well, if nothing else, your first helm looks nice. I found helmets to be one of the most intimidating pieces of armor to make, primarily because of the difficulty in sizing. Try making your own pattern. What I have done with some success: find a kids safety helmet, cover the top in a thick layer of masking tape, then cut the tape vertically. after you peel it off, find the center point and cut radial slits in it so that you can lay the masking tape pattern flat. Once it's flat, you've found your pattern. cut out the leather piece in the shape of the flat pattern, and sew the slits back together. Then do the same for the other side and sew them both together. Once you have the general pattern, scan it into photoshop, measure the circumference of your head, then adjust the length of the pattern to the circumference.
Here is the piece in its pre assembly stage, which I cut from a pattern made in the above manner.
And the finished piece:
Something I haven't tried, but for a more custom fit, put a stocking cap on, and wrap your own head in masking tape.
