Hobgoblinsteve; you did exactly what I did for my helmet, Now I leave this up to you, but I sanded down the sides were I cut to make it more smooth, but then again no one will see them anyway. As far as the ear caps go (I will try to post pics) take your time. DO NOT CUT TOO DEEP INTO THE EAR CAP, Otherwise they'll become too weak and will crack upon assembling the Helmet.
Don't get frustrated when seeing a gap between the ear caps and tube, It is the molding, not your doing, besides there are gaps the OT Helmets (see screen cap reference pics )
Coming along...