Man, that Mickey helmet looks good! It all looks good. Gonna have to improve on my Mickey Ice Cream Bar now. Always wanted to add some white to it so it actually looked like ice cream
I had the "bobble head" syndrome too. Bought a chin strap but ended up not using it. Trial-and-error positioning of the padding fixed the problem. I just kept adding and moving the padding until it was snug to each side of head.
For the thighs, I tried strapping them to the ab piece at first, but later made a garter belt and I like it a lot better.
Here is a pic of the one MightyTank makes:
If you can't get a dremel, then try some small files. Ideal would be a set with different shapes and sizes: round, oval, flat. Jeweler's files will work. They are small and allow you work slowly and precisely.
Not too bad. Most people will never notice. Only people who have built it before would notice. You can look at my pics linked in signature and maybe tell.
I wanted to use the excess material that I trimmed off the thighs and shins for cover strips but I made small cuts and they were too narrow. You might consider that.
Start here:
http://www.whitearmor.net/forum/index.php?showtopic=11538
Research these armors by using the search feature.
Pick the one you like and contact a maker.
I chose AM and paid just a few dollars more than this kit on eBay you linked to.
Stay away from the eBay stuff cause you can get better armor here from known makers.
I'm 6' 3" and got AM. The length on everything was just right.. You would have to trim the width on everything a lot going by your dimensions. I'm a bigger guy and trimmed every piece at least a little for the width.
Thought mine was easy to figure out amongst a bunch of Star Wars fans, but people have ask me if I'm a brain surgeon.
In case anyone hasn't gotten where mine comes from:
"I don't know where you get your delusions Laserbrain." -Leah to Han in ANH
I haven't measured my overall circumfrance in a while, but I wear a size 8 ball cap. My EFX helmet is a little too snug. My TE2 helmet was tight with 2" padding, so I used 1" and 1/2" and it fits fine now.