Awesome, you guys are so helpful. Thank you. I'm definitely into the idea of making revisions, so knowing where these revisions ought to be made is very helpful, thank you.
My first will probably be just straight from the printed template, and as my experience with paper models has taught me, no two builds will ever be the same, and every one will need its own unique kinds of tweaking.
Looks like I'd better be ready for a lifelong obsession. 
@peregrinus - Thank you for all the specifics. Do you have a link to an original discussion of these subtle measurements, or perhaps photos, or perhaps both? I'll still look forward to when WoF's modified templates are released, but I'm not going to wait to get started.
@jinto - You mention Boba wearing the ESB helmet with the ROTJ armour; is that in the DVD re-release of Star Wars? I still haven't acquired it because I'm still kinda pissed about them dubbing the original voice with Temuera Morrison's (not that Jango isn't cool -- and Temuera Morrison's a cool guy, I've nothing against him). But it looks like I'll need to be getting it now, just for kicks. And reference. I might have to play it muted, though, to keep me from freaking out and throwing things at the TV. 
While that mixing of helmet and outfit is unofficial, is it considered acceptable due to its appearance in sanctioned film? Would I be able to get my outfit approved by the local 501st, or would I need to pick one or the other (or just make both separately)?
And thank you for the photo, it gives me some idea of where I should be going with this. 7 in the last month or so...dayum. Looks like I'll be busy if I keep up to your pace.
A question on choice of materials...I know everyone keeps talking about Sintra brand styrene sheet, I wanted to know if these* are acceptable stand-ins, because Sintra is expensive (where I've found it online) and most of the for sale signs I've seen now are in kits with stickers for $6+ each for just one sign, and are made of laminated cardboard half the time.
*Westward Plastics (UK) 23.5in x 48in (1128 square) @ $6 US for 1mm thick, $12 US for 2mm thick
*US Plastic Corp 40in x 72in (2880 square) @ $13 US for 1mm thick, $19 for 1.5mm thick, $36 for 2mm thick
US Plastic is cheaper for more at 1mm, but more expensive for 2mm. They're both different materials, I think; US Plastic is Styrene, Westward Plastics is "Foam PVC." Or are those the same thing? Will they mould and hold shape as well as Sintra brand?
I'll be doing my whole first-run outfit out of the same materials, for the most part, and I'll be making any electronics completely from scratch on my own. I'm not making any promises, but once I finish pulling together my board fabrication shop in the basement, I might start offering chest light kits. I know of fettronics, and the other sold by tk409.com, but I like to make things myself -- both to save money, and for the DIY satisfaction.
And I know this probably isn't the right place for this question, but I'm not sure where best to ask it:
I've seen rub'n'buff do some amazing things to sintra, bringing a jango-like metallic sheen to simple, lowly styrene. If I rub'n'buff-ed my helmet, then painted over it, would the battle-damage/weathering/scrapes-and-scuffs look metallic and awesome? And would the paint even stick properly? Or would that not work in the first place?
