Forearms

My forearms are trimmed and fit pretty good. I clamped them together and using Dave's method I used blue painters masking tape to mask the area I don't want glue on. I will only glue the top of the forearms together as they will be the most visible. I will use velcro on the underside so that I can get them on and off a little better. My arms are skinny enough that I could glue both sides and just slip them on, but it's a little tough getting them out like that. 

Update - I've got the biceps trimmed and ready to be glued. They will be glued on both sides as they can just slip on and off. I started with fitting the legs. I think the legs are the weakest part of this armor (not weak as in thin material, but weak as in they suck). On the legs, the lines don't really match up all that well if you followed the trim lines when cutting them out. The calves aren't as bad as the thighs in this regard. 

Ears are a PITA!

Today I decided to work on trimming out the ears. I once again traced out a line on the ear where I wanted to make the cut. I then followed that line with an x-acto knife and snapped and scored what I could off of it. I then took a dremel -w- grinding stone bit and trimmed it up with that. This is where things got fun. I drilled out the top hole of the ear and mounted it where I wanted it on the helmet. I then pressed the ear against the helmet and marked the spots that were touching with a pencil. I then unscrewed the ear and dremeled off the spots marked to help level everything. I did this for a good hour on one ear before I was somewhat satisfied with the fit. I also trimmed out a little more of the eyes and frown. After looking at the pictures of the frown, I still need to take a bit off of it. 

Update - I got the other ear fit this morning. This one took no time to get it fit as I learned from my mistakes on the first one. I also filed down the frown some. 

I Can See!

I trimmed out the eyes just a little while ago. I followed my pencil lines with an x-acto blade. I then trimmed out the middle of the  eyes with my dremel cut off wheel in order to give myself a way to get some pliers on the ABS to snap the eyes out. I then went over the edges with my dremel grinding stone to smooth them out. I might take a tad bit more off in a couple areas, but overall I'm pretty satisfied. I was going to trim out the frown, but I did not have a dremel bit small enough. I taped the crappy lens material in so I could better see the cut.

Update - I picked up a smaller grinding stone bit for the dremel and got most of the frown trimmed out. I need to get a set of small files to detail it a little more.