I have been looking to add a face shield to the ol suit but plexiglass seems to not quite be up to the task. I bought two sheets of the stuff that cracked or split during the process of shaping them. Does anyone know where I can find clear plastic that can be bent into shape without braking?

www.interstateplastics.com

You could also just look for a motorcycle face plate and try mounting one of those to your helmet. They'd be cheaper and would come properly shaped already. Can get them in clear, tinted, and mirrored.

I have some spare motorcycle face plates if you need one. one each red and blue mirrored tint. They're light in terms of tint from the inside. If i'm out in the daylight i like more shade, so i don't use the mirrored shields.
and i still have my old helmet. I thought it might come in useful as part of power armor buy it don't fit over the bug head.

Thanks, I'll check those out.