Had my first troop last weekend with the costume. Was a lot of fun. Was in it for almost 6 hours which was probably too much for a first run but really helped run it through its's paces and put things to the test.
Some things I discovered I need to work out.
Fett Wrist / Fett Thumb - My left hand flamethrower side gauntlet is not necessarily too tight on my wrist, but the inside lip of the lower shell is putting forward pressure on the wrist right at the base of the thumb pinching a nerve. After a few hours my thumb went numb and tingly and still is a few days later. From what I've read, this is a somewhat common thing but I'd like to figure out a way to mitigate this. Possibly with more foam.
Cod/Kidney Sag - As the day went on my cod and kidney armor was loosening up and falling down my butt lol. I use a tactical velcro inner belt which I may just need to get tighter but since it has velcro on both sides of the inner belt I'm considering adding a few concealed velcro patches around the waist and hip of the suit to help counteract gravity.
Gauntlet hoses - My gauntlet hoses just slip over pegs and are secured with electrical tape. It was apparent that this wasn't enough as the tape came loose a few times and they came unplugged. I might add a dab of epoxy and try to get them semi-permanently secured on the gauntlet side.
Knees Tilting - The heavy weight of the metal greeblies cause the rear of the knees to sag a bit and make the bottom of the knees tilt out. I added even more velcro to the flightsuit in this area but still had some issues with them wanting to do this. Not sure what the solution is here other than to get some lighter weight or thinner knees that can wrap and flex more around the leg.
Jetpack Sag - The jetpack harness I made has elasticity to the arm straps, and is only a 2 point harness. This is causing the weight of the jetpack to stretch the arm straps and thus make the mounting tabs extend out the armor more than they should be. As a temporary fix I want to either shorten/move the white mounting straps to make them shorter, and as a long term fix I want to replace the shoulder straps with nylon or a material that won't stretch.
Armor Scratching - Even though I clear coated the armor, the ab plate got banged up pretty good from my blaster and gauntlets I assume. I don't think there's much you can do to prevent that and honestly the scuffs and scratches that add to the "naturally weathered" look. But I may try and touch it up and add some more coats of clear to it just to add to the durability.
Anyways had lots of fun with the costume on it's first day out!!!! Overall I was very comfortable and cool in it to my surprise.