After a couple years, the mannequin actually held up quite well. However, he was starting to loose weight!
I decided it was high time I gave him an upgrade.
Here's how he looked this morning:

Not bad, but he's getting kinda skinny…
First up, I upgraded the old method I had of making him stand. Originally, I made a giant doll stand for him out of a window well cover (base) a shelf bracket, and a length of u-bar. Frankly, this was a bit of an eye-sore, so i decided to anchor Vader to the wall:

Basically, I took a coat hook and mounted it to the wall. It has a removable ball at the end attached with a screw. I made a loop of leather which runs through the back where the chest-bx strap is. No more ugly base!
On to the refit - helmet and cape removed:

Here's how the wires are run. He's plugged in to the wall so when I turn the lights on to my office, he lights up too:

More parts removed:

Here is the mannequin before upgrades. In the past couple years, I have been adding foam to the mid section to keep the belt tight. Here is what it looks like with all of those foam chunks removed.:

Re-padded with foam all-over:

And the finished product:

I actually added so much girth to his wait that I had to punch a new hole in his belt! He's looking much more imposing now with his new physique!
Thanks for looking,
Chris