The measurements are easy. That notation means fractions of an inch. Best thing is you can have google do the conversion for you: https://www.google.se/search?q=.02375&ie=utf-8&oe=utf-8&gws_rd=cr&ei=tLQbVpn0M4GnsgHR0Ki4Bw#q=.02375+inch+in+mm
As for the bits and bobs, you should just take a close look at some real sterlings and use whatever can can get your hands on that looks like the real deal. There's no right or wrong really. Only better options for those who search long enough (or are just lucky).
Instead of showing us your silicone moulds, show us your real sterling, your real M38 scope and so on. You must have made your moulds out of something, right?
Actually Doopy Doo is a very serious actor and owns every real piece (scope, blaster etc) that is used on his kit.
If you're not interested in partaking, you might as well leave now.
Good helmet. Used to be very exclusive and expensive. Now it isn't anymore.
Looks like any other accurate helmet, with the unsanitized bumps and such the originals had.
It's obvious it's their first time building a stormtrooper and they focus more on the costume than on accuracy. And using velcro is a mistake. It wears out and it has a much higher risk of failing while trooping. And you do not want to loose parts while in public.
Just as with AM, I suggest throwing out the provided strapping kit and doing it with snaps instead if you want durability.
PS, the two snaps in the butt plate is not for "double snaps", it's only one female snap on the strap, because it's for adjusting the tightness.
TM, RS, AP, ATA, MTK, WTF, CFO (for rotj troopers)
There are some of the good ones out there depending on your budget. TM, RS and CFO are UK made. The others are north american.
Beware of resin helmets. They break easier than vac-formed abs, they smell (if not cured properly) and are much heavier too.
We have this for a reason: http://www.whitearmor.net/forum/topic/11538-the-various-types-of-armor-and-where-to-find-them/
Normally I'd say not to trust everything just because it's on the internet. But in this case it's fairly accurate, although overplayed. Still, the official safety data sheet all manufacturers of chemicals must provide is perhaps a better source.
http://eclecticproducts.com/downloads/sds-e6000-clear-english.pdf
Also keep in mind that E-6000 is sold as a crafting glue. For normal people to do hobby stuff with. Not as some exclusive nuclear proof super glue only people with safety clearances can buy without getting a visit from the secret service.
http://eclecticproducts.com/
On the other hand if you're a smoker, that's a lot worse than E-6000, and you're not wearing a respirator for that.
RS has this already.
This mod is for older generations of armour where the butt plate is integral with the kidney plate as a larger piece.
Original film used armour pictured:--------------
It's a bit all over the place. the 15,20, 25 mm is a little "idealized". Reality is closer to Tim's, but that cannot be for certain either. On the RS original suit, some strips are wider in one end than the other for example.
Rom/FX is simply better. Icomm is cheaper yes, but it's relying on a speaker that has built in-non-replaceable batteries. Rom/FX is also more customizable to how you want the distortion to sound.