/cgl/ - Cosplay & EGL

This is probably something /diy/ could answer better but I figured I may as well ask here. Any suggestions for making a plaster helmet stronger? While sanding it down I've come to realize this thing will probably be super fragile at a con. I'm used to working with foam and decided to try something new this year. Any suggestions would be appreciated.

I'm partly tempted just to make a pattern out of what I have now and redo it all in craft foam so that it will be more light weight and durable.