I am currently sitting with SDS, TE, GF and CO helmets in front of me and the faceplate on the SDS looks no flatter than any of the others. It does have the well documented problems as stated by Anson.
Anson I don't think there is a correct or incorrect way of assembling a bucket (outside of putting the faceplate upside down
) its all down to personal choice.
Each stormtrooper helmet used in the movie were just thrown together and each has a different look. The fan made ones we are used to seeing all the time on the forums is the TE helmet which is assembled by Matt exactly the way his screen used helmet was and it does look great and it has now become the standard.
One good example of how helmet builds differ is the two screen used 'stop that ship' and 'move along' helmets if you check the side on picture of them sitting next to each other on
www.starwarshelmets.com you will see that the assembly is very different on each making the 'stop that ship' look flatter as the faceplate is more pushed into the helmet the 'move along' helmet chin protrudes more. Each of these helmets has a distinctly different look and even though both are screen used I have a much greater prference for the 'stop that ship' helmet and its look.
As for the price of the SDS remember something is only worth what you are willing to pay for it. Your buddy should have maybe considered going for one of the new 'set for stun' TE helmets.
Anyway I am sorry you and your friend are so dissapointed with his purchase. Hopefully a wee bit of assembly changes might help.
Cheers Chris.