That's a great find!
Lots of work, and a lot of equipment. So nice to have such things on hand as you can see how valuable it is. Can't wait to see when it all starts coming together and the painting process. Absolutely gorgeous.
I really don't think the pvc endoskeleton is necessary at all.. My suit stays in shape pretty much no matter what I throw at it.
My legs aren't attached to the wait at all. The thighs are connected to the shins, but that's it. They rest on the boots, which might be a tad wrong but it's worked so far.
One thing you can do to prevent the straps from cutting into you is to go with wider straps. I can wear my harness for Snake all day, even with every pouch loaded to the gills (about 30lbs with a full canteen), and that uses 1.75" straps.
Edit: Also, going with a modified version of a modern load bearing harness may help, too. Take a look at how SPIE harnesses are made. The crossover at the back and sides help with distributing the load over your entire torso, and not just the tops of your shoulders.
If you have any significant load on your shoulders, you're asking for problems. The best approach is to put the majority of the load into your hips, much like hiking/military backpacks. Shoulder straps should just be there to spread the load.
That being said, professionals use SFX harnesses.
Wow! That looks great! How did you trim the shoulders? Did you just choose a piece in the middle and cut it out, or did you cut off the bottom?
I created a harness with 2" nylon straps and used foam as a sort of padding over the shoulders. Seems to work pretty well. I also bought a harness similar to the one above, but its awfully heavy for this project. Might save it for my next project.
Now that is fantastic! Love the little skulls and the crosses on the belt! Did you buy those skulls or print them?