Way better! Awesome- the JB weld or putty you used method really seems to be the way to go, with the painting afterwards. Straight ABS paste will work, but so much more work to me to get the correct end result.
It seems with all of the different makers of armor, you dont often see the perfect alignment of the kidney notch, ab plate and butt plate. No need to cut the butt piece.
Looking good! Yea those corners on the belt are a little sharp; also your blaster will need the lt bottom t-track shaved off and holes then drilled (I had to do the same on my EIB app!). You could pretty easily drimmel out the scope rail filler if you wanted also while the tools are out!
No way to simply not abutt the forearm pieces, but leave a small gap that can be covered by the regular size coverstrips? This should give you almost an inch extra of room and will not affect the look.
NICE!! Great job. I agree on moving the chest down- on the front arms down with helmet pic it looks like you can see the top of the ab plate showing. Your chest would probably slide under this while trooping.