Locitus

Second point isn't very clear. But Germain is correct, the real suits, and the idea of the CRL is that ESB is the same as ANH.

Very nice!

You don't need a frown mesh, strictly speaking. It's just something most people put on.

Both RS and Troopermaster make fine, high quality armour and you can't go wrong with either of them. As for your budget, as frustrating as it might be, just take it easy and keep saving. You're making yourself a service by getting it right from the start, or you'll end up spending more to fix past mistakes.

A small dab of glue behind the brow should help it stay where you like.

Yes, only the frown and vocoder were hand painted. As for the frown, it's the same as ANH, except it's black.

Inner strips on a overlap build? That's 3 layers of abs!

Pretty interesting overview of what led up to the development of our beloved E-11. https://www.youtube.com/watch?v=8-PmLxkOmaM

It's quite common.

Dollar store items suck? I'm shocked!!

There are rechargeable 9v batteries too. As you've noticed.

The whole armor is not made of acrylic, it is still mostly ABS, with a thin coat of acrylic to make it glossy. It's still pretty flexible.

Hi The original suits were made from 1.5 mm ABS, but 2 mm is a bit glossier (unless TM has acrylic capped 1.5 mm too now) and the more popular choice I believe. The 1.5 mm is slightly easier to build however, since the plastic is thinner it's easier to trim and cut. At your height you might want to ask TM for his extra long shins.

I'm 5"10' and 60 Kg and I'm using a TM with good results. I had to slim down the arms and legs a fair bit since I don't have the girth but it doesn't show at all if you do it correctly. I built my kit mostly on my bedroom floor with a blade and a pair of lexan scissors. For the gluing you'll need some clamps but mainly lots of strong neodymium magnets. And masking tape. Also get yourself a piece of wood to put on the floor so you can hammer the snaps together nice and tight.

Ah, that makes sense. The picture I'm referring to is this: As you can see in our ROTJ gallery that's how they look inside, not how the ANH helmets do. http://www.whitearmor.net/forum/gallery/album/35-return-of-the-jedi-misc/?st=50

I'm curious, you know that the lenses are supposed to be green (even if we do allow grey at the moment, something that can change at any time) why not go green lenses? PS, you're mixing references, the s-trim helmet is ROTJ. Be careful about mixing movies since they are not necessarily compatible.