The replacement arrived today.
Already popped some quick pics.
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Comparison of the old helmet (left) with the mandible issue, with the replacement helmet (right). Please, I'm not standing the same distance from these helmets, so the shape is off a bit. But you can distinctly notice the mandibles are much better on the replacement helmet on the right.
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On another note - there is a slight spiderweb cracking in the paint on the replacement helmet. It's not noticeable unless you pick up the helmet and inspect it for flaws. I do like the weathering on the replacement helmet more so than my first helmet. Seems like there's less "pastiness" on the cheeks, and around the mohawk. Everything else is sharp, and no wavy lines.
I posted on the RPF, that while I'm very happy with my replacement, I know there are going to be others who aren't happy with their helmets, and eventually EFX is going to run out of replacements, and their only response is going to be "There's nothing we can do". This is especially true with the people in the second wave, who receive their helmets in the last shipments.
EFX might need to rethink how they sell and produce their products to avoid these issues. I already noted, they could take a cue from RS Prop Masters, and reduce their productions to 25, 50 or 100, make sure everything is in tiptop shape, then sell another run of 25, 50 or 100 - until their limited run of 750 is fulfilled. It takes longer, but it eliminates the "rush job" of trying to cram 750 items out the door all at once. Or take the 750 orders, and produce and ship them in batches of 50. It may take a little longer to fulfill the orders - but if they keep everyone posted, and the communication going and flowing, it would certainly help.
Plus - move their production to the US so they don't have to ship items from China to the US through customs, then ship to their final global destinations from the US.