It's interesting reading about the suit being difficult to build. I see lots of builds where the suit it put together so it all fits together perfectly, with uniform return edges and looking amazing, but, that is just not how the original suits were made. They were rough, really rough, I can't stress that enough. Return edges that look like the we're hacked at with knives and scissors (I don't think the dremell exsisted in 76). The suits were thrown together, all the same size and trimmed out as an when required. The leg cover strips are 20mm, some are 23mm they run out of square so can be 20mm at one end and 23mm at the other (25mm shin backs).
Rolf, I like your comment about unlearning, I think you got it there. Take a step back and just jump in. Start at the front cover strip, the back will be what it will be. The torso really looks after itself, trim with a return edge just big enough to take the bolts (if using them or not). Maybe the worst trim line is the shoulder bell. The original is rough, trimmed with scissors. When we formed them we had no idea where to trim the fresh plastic. So we created templates to trim to, which we mark on every set, as we do with ears internally now to help get a better fit.
If you try and build the suit too perfectly it will be a difficult build, and it will not be the best result. it's a replica of an unperfect suit and that's the point, the details may look rough on thier own, but as a whole it's, we'll perfect.
Rob.