Our internet connection here at SDCC is just horrendous. I am sure Gino will chime in when he gets back, but I can give you the general gist of what he is going to tell you.
What you are essentially asking for is an unmodified copy from the mold. There a couple of reasons this isn't feasible, and most of it stems back to the fact that eFX is a business, selling large quantities of items to the general public. Also, it is simply a matter of practicality.
So let's talk about it a bit since I have been in your shoes and asked the same questions.
First, you have to remember that the way the ESB helmet looks today is NOT the way it looked during filming. Over the years, the surface of the helmet has developed a number of cracks that weren't there at the time of filming. There is a very prominent crack up the temple of the left hand side that wasn't there as well. eFX wants to offer the ESB helmet as it was... not as it is. So... those issues have to be corrected.
Beyond that, there is also "texture" on the surface of the helmet due to the many layers of paint and weathering. No matter what anyone believes, even the most masterful painter couldn't use those and paint over the existing paint marks with new paint and make anything but a muddled mess. That means that in addition to the cracks being removed, the surface of the helmet has to be ever-so-lightly sanded to remove the thin layer of paint and take the helmet back down to the smooth surface. Many believe that the surface of the helmets have physical damage on them (primarily because of the dremeling that Don Post did on their helmets) but that is not true. Below the paint, the ESB helmet is smooth. There is no texture or damage except in 3 of 4 key places (all of which was left intact).
Now.... about production in China. You have to realize the people ultimately making these helmets don't know who Boba Fett is and wouldn't care. They don't know what a damage mark it and see that as a casting flaw. eFX has to go to the factory and provide insanely detailed instructions on EVERY SINGLE SCRATCH they want left in place to ensure the factory doesn't assume it is simply a casting flaw and putty it in. This is a very tedious thing to do, but that is how it is handled. To give them a mold that was covered with surface texturing (from the paint) would cause their heads to explode. It would also look absolutely ridiculous once they had repainted the helmet.
Now, you might ask, why they can't offer something less touched up just for us. The truth is, you would still have the same production issues, and there simply aren't enough people here, who would want a helmet like that to be financially justifiable, not to mention Lucasfilm would never approve a product that they felt looked terrible and broken, no matter how accurate it actually was.
Agreed.
I don't understand why it must be "cleaned up" at all. We'd all prefer seeing every single detail.
Gino can you educate us as to WHY is has to be less than a direct cast with masterful paint?