troopermaster

I would have to disagree. Not trying to be contrary, but I think it's wrong to state they were thin just because the one in the photo you posted is. As with all troopers, there are slight variations in the assembly, trimming and detailing, so I think it's only fair you allow the same when judging someone's armour.

The ear 'could' be saved. Try trimming the front more to bring the back side of the ear into place. They usually need a bit of gentle persuasion on the lower end anyway so don't be put off if it sticks out a bit. Give it a try and see how you go

Looking good so fare Give the ends of the mic tips a rub with some fine/wet and dry sand paper for a sharp, clean look

You say 'acceptable' as though there are some kind of rules. It's your helmet and you build it how you like. Stop worrying about minor details and enjoy the build. This place has got everyone panicking about details and taking the fun out of builds. Get the ears on, get painting, get trooping and have fun!

The most common mistake people make when building a hero helmet is to tilt the face upwards to get a low brow. That is not how to do it if you look at original helmets. Only one hero helmet had a really low brow and it had a gap between the brow and face on the forehead (as most hero helmets do). You can still build them tight with no gaps and overlap the sides. You just have to play around with the positioning of the face.

The shoulder bells are a different shape from left to right.

Here are the photos I promised. As you can see, no gaps. I am not sure how you got those? You might want to reposition the face better. Don't worry about drilling extra holes in the face, they won't be seen once the helmet is assembled.

Yeah, they went ages ago

Luke also wears two left shoulder bells. And not to add confusion, the BW photo in the image above is not Luke or Luke's helmet Great job on the build. My only critique is that no flashing was left in the eye sockets, making the eyes look big. I like the fact that you trimmed the top of the left thigh just like Luke's. Overall the suit looks awesome. Well done

Two rivets per side are all that's needed. You are worrying unnecessarily about minor gaps that get covered with the ear caps. I will take a few photos soon of a helmet I have just assembled to show how it's done. Everything is looking fine so far

"So will everyone be ditching their stormtrooper outfits?" Nah, not a chance! The original ANH is, and always will be, the best costume to own. I'm sure the new version will be a great addition to your costume collection, but the ANH armour will take pride at the top

Simply roll one end around the plastic tube and then mark of 75mm on the other end and bend it over a screwdriver shaft to get a nice bend. Drill your holes for the screws after you have bent the brackets or they will kink when you bend them

You might want to check out the Hero teeth references instead of the Stunt posted above

The four rivets are for helmet assembly - two on each side.

You have hero helmets with separate bubble lenses. You need to glue small squares of ABS in each corner of the eye sockets to build up a base to stick the lenses to. I have found this method to be more than adequate in the past

There is another option.....

Looking good HP! Loving the weathering. Great to see a trooper that looks like he has seen some action instead of the usual squeaky clean armour. Good luck with the your application

You could do that, but it won't alter the angle of the face. You should reposition the face if you really want your helmet to be like Luke's or just be happy as is and make a nice, non-specific hero helmet. The hero helmets are quite hard to get the right look. There is some jiggery-pokery that needs to be done in order to make them look like the movie helmets.

If you really want to make it like Luke's helmet, you will need to reposition the face plate. It's a common misconception that Luke has a low brow that covers the eyes. If you look closely, you can see white between the eyes and brow. To do this on your helmet, you will have to drill out the lower rivets and pull the face inwards. You can see in this next photo that the face actually tilts downwards, not upwards. And in this next photo you can see there is a gap between the face plate and dome, meaning they are not pushed tight together. Your eyes are looking quite good as is. Maybe take a touch off the lower edge but leave some flashing above.

The original strapping works better than anything but it has to be used on the right kind of plastic and fitted correctly. It was not the strapping method that failed, it was the application that was done incorrectly that resulted in the failed part (popped rivet). The person who assembled the belt did not do it properly so it was his error - not the original strapping.

I give up

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Really? ----------- The thigh border has been cleaned up somewhat

The armour looks as though it was cast from a Don Post statue.

Not getting approval for having the extra hole cut out is pathetic! It's time to start acknowledging Stormtroopers are not clones and some slight variations (as long as they are true to the movie original costumes) should be allowed.