When they sent the model they recommended using meshmixer's analysis tool to correct any issues. The problem with this was that there were multiple issues and using meshmixer's auto-repair function eliminated a number of details and complete parts disappeared (a few were non-manifold, like the bicep guards).
I scaled the armor to my height, converted to mm (which my printer operates in) and separated all the shells and exported them to work on individually. To combat the numerous problems I encountered with intersecting shells and zero-thickness walls post-slicing to fit on my printer bed I ran all the exported bits through netfabb's online repair tool; which worked like a charm.
https://service.netfabb.com/login.php
I also experimented with meshmixer's make solid/make hollow, extrude and minimum thickness settings to do the same corrections (the previously linked Makers Muse has tutorials which cover these, thanks again Angus!)
Now that I had all the parts separated and corrected I needed to check their virtual fit for accuracy.
First I tried Autocad's Remake (the new version of 123D Catch)
http://www.autodesk.com/education/free-software/remake having the wife take several rounds of photos around myself to create an accurate 3D model. We weren't using a tripod or anything and it likely showed in the result, with shrivelled appendages and tumor-like blobs poking out of my head. I clearly also had too many clothes on, so I tried again....and it wasn't any better.
I then turned to Makehuman's product (
http://www.makehuman.org/) as per the ultra helpful posts from TKCC71 (
http://www.therpf.com/member.php?u=148751). His IronMan Mk 46 build on here is epic!
After inputting my measurements into the program, tweaking the depiction of myself and importing it into meshmixer alongside the scaled Do3D armor, I was able to size the individual pieces appropriately. Pretty much only the waist portion needed to be elongated to fit better (or so it seems prior to printing).
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