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Yeah, mine looks quite different, and does not have the 'angled out' cut on the sides. I'll have to think on this one a bit more.

Thanks heaps - definitely more to take out of the biceps. Most of the others seem to be in line with those guidelines. Cheers [emoji1360][emoji380]

I constructed my own TK from the WTF ANH kit, and I also found some of the areas to be a little tight. By chance, do you have return edges around the openings to the top and/or bottom of the bicep? If so, that may be contributing to the issue (if the problem is when putting your arm in and taking it out). As you can see in some of the reference photos that Glen posted, the armor used in the film lacked return edges in many areas, including the bicep.