From Prowse's website:
"By the time the 1960 Mr. Universe contest came round I'd blossomed from a start of 6' 5" and 11 1/2 stones (2meters and 75k) to 6'7" and 17 stone 31bs (just over 2meters and 110k)"
Prowse was a big fella:
I think almost all mannequins need bulked up to achieve those kind of proportions - unless there is some huge bobybuilder-type mannequin out there avilable for sale. Prowse also has rather long arms, wheras most mannequins have fairly short ones.
I've put a lot of work into my own Vader mannequin, adding height and bulk - I've redone this process several times until I am more or less happy with how it looks. As has been mentioned, it's especially important if you are using Prowse sized armor too, but even the GT size stuff looks better with some added muscle on the mannequin to flare the shoulder bells out a bit, IMO.
I think when it comes to bulking a mannequin out, attention must be paid to achieving the correct proportions. I agree that the last thing anyone wants is a fat Vader, so the majority of the added bulk must go to the shoulders, chest and back, biceps, forearms, thighs and calf muscles - not the midrif.
My Father-in law worked on a Police training video with Prowse circa 1980. My Father-in-law is 6'4, and Prowse was approximately 2" taller than him. Based on this firsthand assessment from a trusted relative who has no interest in Star Wars etc, I reckon Prowse stood at around 6'5" to 6'6" in his prime. Yeah, I agree that 6'7" is probably a little exaggerated.
I met Prowse last year and spent a little time helping him move some merhandise from his car. He has had his health problems and this has certainly affected his height - I guesstimate he was around 6'4, although his posture makes it difficult to tell now.
Al