Hey Jon, I'm a newbie here at 5'10" at 230 pounds. I chose NE armor because it accommodates my large size. I hope when my costume is done, it will inspire larger newbies to join us. You're not alone. I'm sure the more of us speak, we can all feel better around good company. Someday....someone will say... "Aren't you too fat to be a Stormtrooper?" My response will be... "I'm Vader's Heavy Calvary.....We get the job done!"
As i'm working on my build, I do get frustrated because I see a lot of fit troopers getting help and guidance faster from other members. They don't have to worry about shims, hiding their muffin tops and wide butts, or sucking in their gut. After finishing my build, my big worry is being told I'm too fat for approval and I have to do "this" and "that" because my armor is not screen accurate. I kinda wish there was a trooper about my size that can help me out. I've been stuck for weeks, but I still keep a positive thought that - - - " I can overcome being larger and make an awesome costume. "
I had a long talk with my fiancee about this project and she says, "it doesn't matter what others think or say....you're doing something you love....and that's Star Wars!"