It started with the Flametrooper helmet. I should've stopped there. Next thing you know, I started making Captain Phasma's chrome helmet. Then, determined to drive myself insane, I got started making the rest of her armor. At that point, all hope was lost.
It started when someone in the workshop says, "hey, it looks like the new TIE fighter pilot has the same chest armor, shoulders, gauntlets, and belt as Phasma and the stormtroopers*"
"Think so?" I ask.
"I'm pretty sure," says he. "All we'd have to do is make another helmet and the chest boxes and then it's just a matter of painting everything black and finding the right flight suit."
"Piece of cake," says I, being as wrong as possible.
So before anybody sobered up long enough to think better of it, I'd contacted the ever-ready 3D modelling folks at DO3D.com and got them to work on the helmet model. As usual, they knocked it out of the park:

Then the madness continued.
The results of the madness? If you were at Wondercon you may have seen a few of these guys out and about:

For more details on how they were made, read on...