Have a sewing machine? If yes I'd trim it back to within 1" of the Velcro closest to thearmor. If no machine check with your GML, they'll give you some honest approval advice.
ABS paste works great, though I've also used tub and tile filler on a couple armors, So long as the color matched it works beautifully, not to mention there's no gluing, sanding or painting. Oh and the armor is ready to wear in 30 minutes lol
IMHO think the brow is just fine however, the CRL is changing stating there should be an some white seen underneath. If you plan on shooting for the higher levels you might want to raise it a bit.
Greblie? Apparently there's some inaccuracies. I'm sure something will come out in the CRL update whenever it gets started, til then build away.
How the yoke and back are assembled is pretty clear, especially when it comes to the seamless areas. I don't foresee any changes to the CRL that may contradict what's screen accurate.
There a few solutions to prevent this from straps to snaps to velcro.
I simply place a 1-1/2" square patch of white Velcro on the front upper portion of my boot and the same desired area inside my shin. It's worked for me for years.
Thighs look awesome, don't forget to paint the rivet heads.
Me neither.
In my opinion this also goes for the snaps. Use good quality snaps, I personally use DOT or Fasnap, very high quality. I use the single snap method and I've never had a snap fail. I know some people use double so it's completely up to you.
Minor gaps between the ears and helmet are perfectly acceptable. As Lou mentioned try to align the upper and lower ear screws with the trailing edge of the trap. FYI neither have to be perfect.
Adding additional material to hold it down is completely up to you and no it will not have any bearing on any level of approval. That said, if you have enough material attached to the bell (I use at least 1-1/2") and allow the glue to cure completely you'll be fine.
As glen mentioned if possible 4-5 rungs on the chest plate, how many that remain on the back doesn't matter really so log as they're relatively centered on the back plate tabs.