Speaking of the single combiner, I don't think I'm going to be using 2-way mirror for this. Let me explain why.
This made me realise that I don't just need to see the outside world, but that there has to be a good amount of light coming in too.
I've printed some 40mm "cubes" that should give a geometric and visual indication of looking thought the beamsplitter. Due to the shallow angles between the faces I've printed on the actual beamsplitter cube, those faces would reflect light and not allow light to just pass through.
It's... okay. 40mm is slightly too big, but the PPD calculator says that I won't be able to do a 30mm cube with a 25mm eye relief at 90PPD. I could do 97.5PPD though, barely. 35mm sounds like the nice middle ground. The "optical bezels" are also quite large (like 30% of the width of the see-though area), but because they're a medium-light grey instead of black, it's not so bad actually.
Speaking about the price, it sure increases fast after 25mm^3. I coudn't specifically find a 5:5 35mm^3 but there are 40mm ones where the listings usually say that the cube can be customised and those ones are £50. Now that's a lot of £££, but I'm struggling to compute a solution using the much cheaper but quite thin beamsplitting panes since they seem harder to mount in the 300mm cylinder and I imagine it visualy looks worse from both the first and third person perspective.
The 300mm helmet visibly looks nicer to move in, but the real bargaining chip it has is that I can buy a 300mm acrylic tube section but I can't get a 350mm one.
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I think I'm going to try a 30mm cube and only if that doesn't work try 35mm.
Are you sure? yes | no