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Do what you said about the sanding and cleaning to make sure everything is as smooth as you can get it before painting, and try to get a good test fit posted here so we can make sure you're good to go as far as sizing. The mavericks look good but I just can't shake the fact that they still look like mavericks to me. I think you might want to try to mod them a tad more to eliminate that resemblance in the revolver section. It might be cool if you can figure out a way to make it like a tri barrel cylinder block instead of the stock maverick cylinder block.
The bucket looks fine, minimal padding in the top though. For the size, dont worry till you get all the armour put together. The helmet looks oversized only cos yeve no got,(a) Flightsuit on(b) Flackvest on(c) Shoulder bell's onOnce all of these are ON it will bulk you up big time, especially if you get the shoulder bells right.
Thanks for your input guys!! I'll hold some shoulder bells up in the mirror with the helmet on, just to see how it looks.As for the helmet padding... my old HJC CXL-4motocross helmet padding fits perfect. Thinking about just using that, since it's got some good sweat-wicking material in it too.Edit: I looked in the mirror, and honestly it's hard to tell without the whole kit put together. I think it'll look fine. There appears to be a lot of variance in helmet-to-shoulder ratio on Jango & Boba's kits in the following photos:http://www.starwarshelmets.com/original-boba-fett-jango-fett-helmet-costumes-armor.htmLooks like Jango's helmet is skinnier vs his shoulders (b/c he is broader than Boba). It also looks like the ESB Boba has a wider helmet than the ROTJ Boba. It could be perspective, but they do look different in width.Looks like the light is reflecting off the bare-spot on the helmet, making it look flatter than it is. I threw a quick layer of paint on it to see how "flat" that side is.