I would remove the ears, then sand and contour them to fit a bit better to the helmet. You will always have some gap though, but yours can be reduced down a bit....
As the lone EIB TKC, I have to say that your kit looks great, just a few tweaks and you would be there... I know that I look at mine and want to play more with everything...
I took apart and thought I carefully removed the voice changer from my Hasbro clone helmet thinking it would fit great in my TK lid. In order to get it out clean I had to remove the wires from the battery box and the speak...when I reattached the wires I think I reversed the battery box ones and the switch heated up on the board...I quickly removed them and put on properly..no the dang thing won't work...any suggestions???
6'2" , 265 here...check out my EIB thread...the ab/cod are 1 piece and the back/butt is separated......added pieces on the side that are velcroed to the ab and back pieces....
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