Hey Fangs,
I am having the same issue with my shin pieces... they will redyed again today for the third time, trying to get them right.
My neoprene shirt is also too tight (around elbows and shoulder points), and working out with P90x just made that worse. After my deadline in 11 days, I'll be making a new shirt.
Are you protecting your dye on your shins with an atom wax or resolene? Be careful cause water dripped on it right now will cause a white or tan puddle. If your troop is indoors you should be okay.
Get the hat brim wet and try fitting it again. Of course, you and I reshaped our helmets, so it may just be too far off to fit at all.
Greeblies look awesome! Keep going!!!
Deunan