Thanks for the interest people ...
Its slow progress at the moment due to other projects and money etc ..
But to answer a few questions, i have decided that i will not be using vac formed Armor pieces now (not directly on the suit anyway) as i have since learned that most of the small armor pieces were actually cast in a type of urethane. So i will vac form the moulds and then use them to make the Urethane positives for the suit.
The Helmet lenses in the pictures are actually vac metalised abs (like C3P0) which im just using for testing the appearance as you cant actually see through them .... i have some clear acrylic ones waiting to be gold coated at the moment (like sunglasses)
The teeth are about to be reprofiled to look more aggresive and more like the originals before they get metalised and weathered.
Im also looking at the best way to fix the rear part of the helmet to the front ... i think possibly a small hinge and some small earth magnets at the sides is the best route at the moment ... then that can be painted ...
Anyway, i will try and post some more progress pics over the next few weeks so you can see whats going on .....
.... and thanks again for the comments and interest ...
G.