The reason why the helmet has more flare in ESB is because the eye corner and mandibles were not damaged yet. It was damaged after filming. Once that eye corner cracked it offset the alignment of the brow line and the mandibles and therefore reduced the flare.
The kind of flare you are talking about, from sitting on a shelf, is from the mandibles spreading apart from the weight of the helmet over time. In that case you see the bottom of the visor widen significantly. There has been no spread of that sort on the original helmet because the mandibles remain secure.
That crack in my helmet was a crack I opened up myself earlier in the thread. You might have missed it, but earlier in the thread I showed my process of taking an MCR-ESB (raw G2 cast), where I sliced open the cast-in crack damage in order to realign the broken eye corner to it's pre-damaged state. In widening the flare I reopened that patched up crack, which only proves how much tension is in the eye corner, and hence probably why the original helmet cracked there in such a catastrophic way in the first place. And once that crack happened to the original, it released the tension holding the flare in place, and settled into state of lower energy, never to be recovered again since the structural integrity necessary to hold the flare was lost forever.
