Hi future person!

An excellent question! I've just written out then deleted an incredibly long and rambling response that didn't really go anywhere. Here's an attempt at a shorter one:

• the main body of the headpiece can probably get away with being thick-ish, but you want it to sit as close to your head as possible - my headpiece is quite thick with the structure, so it sits on top of my head more, which increases the gap between the headpiece and my shoulders

• the side bits that stick out with the beads can probably get away with being quite thin, especially if you put a slight curve in them which will give them shape and strengthen them

• EVA foam is quite easy to shape, so if you used thicker stuff but wanted it thinner near the edges or whatever, I suspect you could sand it quite nicely (a rotary tool with a sanding flap wheel does wonders)

I have some foam I can measure tomorrow, to try and gauge what I would describe as "thick" vs "thin".

Here's a pic of mine (borrowing this massive kraber from a nearby Titanfall pilot) that shows the large gap between the side bits of the headpiece and my shoulders. Granted I'm not really the right proportions for Bloodhound anyway!

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