Looks like a good project for masking tape...
Speaking of which, I’ve been very thorough in that I replicated both an accurate and an idealized version of the black faceplate.
As noted, the faceplate was clearly molded into the body and then masked off and painted black. Which means that they certainly used straight-edge tape on the sides to mask it, and that the left and right sides of the faceplate therefore didn’t actually follow the curvature of the face of the comm body.
So, I replicated both a straight-edge version, and an idealized version that follows the curvature of the body. That being said, the difference between straight-edge (left) and curved edge (right) is so negligible—especially at this scale—that I’ll just go with the idealized version. And I’ll also do it as a separate piece, for ease of painting.
Also, based on my measurements and modeling, it’s become very obvious to me that most replicas of the comms are WAY too thick. While trimming of the resin and vacuformed bodies definitely varied, they comms are by and large very thin.
The replica I just re-decaled has a minimum thickness of around 10mm on the lower/thin half of the body. The 3D model I’ve recently built has a minimum thickness of around 6mm—nearly a 40% difference.
And, apparently due to molding and trimming variations, some of the screenused comms have sharper edges, and some very soft/blunt edges. My model has the crisp, sharper edges.
I’ve also noticed what appear to be variations in the width of the wristbands from comm to comm. Some appear rather wide—akin to the 1” bands on my own builds, and others thin (maybe 3/4”, or even slimmer).
I’m also wondering how hard it would be to actually replicate the Super Hero’s electronics and fit it into the comm body.