ABS80

its innaccurate, hero helmet should have only 3 bumps on grey ear section not 4 which is for stunt, and mic tips are not accurate.

yes it is.

looking good, great job so far

Change those mesh, they are totally inaccurate.

Plaster is not strongs enough but good luck!

AP are also accurate, here is a photo of the Italian garrison in Rome wearing two AP costumes. ----------

Best is to fill the recess area with a piece of scrap ABS then fill seams with abs paste then wet sand /polish, avoid using full bondo/ fillers it will just crack or chip in time and color won't match, using the abs from same plastic and abs paste will be a perfect color match.

The notch should be lower than the AB not flush, don't round off the corners of AB they should be square, DON'T RELY ON JUST ONE PHOTO! I purposely did the AB extentions at a proper angle so it doesn't affect the positioning of the kidney plate so the "L" sits in correct place even at full extent. As you can see the AB and kidney are flush at the top and the notch is lower at the bottom. This is the correct way.

There is other options for much less!

You can easily join two shoulder straps togheter to get the length desired, just do a straight cut between the ribs and join the two halves together with a thin piece of abs strip full lenght at the bottom of the straps using ABS glue, the seam will be invisible. But if chest is too small for your size the best solution is getting a AM chest and back though not screen accurate in size but at least it will fit you.

AP is now concidered the biggest of all screen lineage suits with a much bigger mid section and leg parts ect.. actually my shoulder straps are longer than movie originals with over 2 inches extentions so people can cut to size. All trooper costumes that have lineage to movie suit have same size chest and back piece, meaning RS, TE, ATA ect... even Anovos and TM are very similar in size, the only larger chest are the FX, RT I believe which are fan sculpts and totally innacurate, in my many years of trooper making this is the first I hear AP chest is small. Mark (AP)

Great job looks much much better! I see that they heavily modified the frown shape extremities to simplify removal of face plate off molds, that area should be square no at angle blending into side tubes. ------------------------

yes remove completely top and bottom

Depending how deep is the scratch, wet sand using 1000 grit then 1500 and finish with plastic or car polish to bring back original shine, you will never notice. The easiet and fastest way to cut out the frown holes , is to use a dremel with sanding drum from inside until you make hole then use exacto to square off holes from the inside. Mark (AP)

for the bicep align the bottom, the upper should be offset like original, check my photobucket photos of assembled biceps

Inner forearm parts should have no return edges. Mark (AP)

Good job on the helmet! a metal ruler is very handy for cutting straight lines especially the shoulder straps, don't forget to leave 1/8 lip on each side of shoulder straps, many tend to remove too much material. Mark (AP)

That's not a bad pull, the mold is designed like that, every single helmet will have the same exact issues, also noticed there's not a 5th tooth it's just a void no material, basically there's not a unpunched tooth like the original.

It's custom formed to your body, they fly you to China for free and vacuumform the armor parts directly on your body, beware it gets extremely hot in those machines LOL!!!

I don't make parts on demand, I do end up with extra parts which I put aside for replacement or to sell. Mark (AP)

Will definitely rework the inner boxes, I was so behind schedule we started the pulls without having a chance to test fit, my main concern was the new body armor parts which was a real pain to form properly because of the added size to the molds.

the only solution to resolve this would be not put any notches, but then every single person would have to cut out the notch, not sure its a good idea since repositioning of the notch is only required for over 36" waist. Mark (AP)

Never tried the hobby iron, try it on a piece of scrap.

I don't recommend a heat gun, ABS requires a lot of heat and as soon it reaches malleable temp it will just shrink/warp because of the high rubber content, I doubt you can pop out the return edges with a heat gun without damaging the plastic. Mark (AP)

the notches on the movie original did not line up perfect with the butt plate and mine has the same issue, but you won't notice because both part are never flush when wearing armor. Mark (AP)