Here are a few things you can do to get your vacu-formed armor a little more accurate.
1. Cut the holes out of the chest, chest vent, shins, and biceps. Back them with a black cloth material. The material should have a brick pattern to it. Like as in a brick wall, staggered rectangular pattern. Something similar to this...only all black...and ...yeah
2. Use a sanding block on the ab boxes, left shin boxes, and forearm squares to sharpen the edges. We CA glued these on, but I like what other folks are doing using screws/bolts on the inside and drilling through the ab plate and securing with a nut. Any gaps between the boxes and ab can be closed up with either bondo, CA glue, or white caulk.
3. Cut the chest "wings" and reassemble using a strip of ABS or styrene on the back, realigning the two pieces to make a noticeable seam. Bondo the return edge on the top and bottom. Also, either sand out or use bondo to fill in the "shadow" seam line. It's subtle, but noticeable on most if not all chest plates...to the outside of where the seam actually is.
4. Biceps- Fit these as you normally would. If you need more plastic, add it during this step. Assemble using butt joints on the outside. Overlap the inside but use velcro to close it. Now, cut the seam line where the steps are, where the resin buckle gets glued. Back with ABS or styrene and realign the pieces making a nice straight seam. Leave approximately 1/8 of an inch gap. Cut out the little steps and toss that piece at your annoying cat. Replace that soft detail with some thin styrene or ABS or some modeling siding from a hobby shop. Cut to size and back the empty hole with ABS or styrene and glue in your newly made, shaper detail piece.
5. Use 3/8 of an inch neoprene foam under your floor mat belt. It should go Nylon webbing, neoprene, floor mat.
EDIT [Daetrin]: using cordura nylon works well too...
6. For the two belt boxes..10H and 10K, use plain silicone rubber with a smoothe finish as the bottom of those boxes. Keep the ABS bottoms that came with you kit for trays to keep odds and ends in. With that rubber piece, 5/8" on the outer edges and 3/8" in the middle. You will have to cut a bend in the rubber so it matches the contour of your floor mat belt. If you don't, the ends of both boxes will flair out or stick out because they are flat.
7. If you want to be uber accurate, use velcro to close the inside of both thighs.
8. Cut two notches in the top of the yolk where the shoulder bell meets it. Use a chunk of steel or sturdy aluminum in between the notches sticking out toward the shoulder bell. Metal tab should be approximately 3/4" wide, 1/16" thick and protruding from the yolk about an inch. Use two 1 inch wide straps to connect the shoulder bell to the yolk.
9. Forearms: Only glue about 75% of the plate with the long greeblie. Leave the wrist opening unglued about 3 1/4 inches back. This will also help get your hand through without skinning up your hand.
I appologize for the photos as most are taken with my phone. :-/