Paul is 100% on the mark, I believe. As you know, the 501st costume standards really only care about how the costume looks from the outside, so as long as it is cosmetically correct that's all that's judged against. As the saying goes "if I've done it, it's not impossible", Paul has put together numerous suits using accurate methods, so it would seem to be more of how it was built one would think. Or, even if using correct methods, sometimes mistakes happen. I've been worried about long term troop-ability too, but one person in my garrison has a suit made by Paul and he troops the heck out of it, and it seems to hold up just fine.