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that looks cool vod It reminds me of something...... but i can not remember what
Yes ears remind me of voltron, thunder cats, optimus prime ears from when I was a kid. Could be cool though. Can only try and see vod.
I agree with what the others have said on the plate sizing. Just use the outside edges as a guide and come in the same distance all the way down. That way you have a new line to cut at that matches the original. Also the pants you will be using for your flightsuit are rather baggy on you, I would take those in a bit.
If its something like the mythosaur skull or a clan logo, you could print out your design, use an exacto knife to cut it out (like a stencil), and then use spray on fabric paint. if its a picture like of a sunset or something, either the iron on or hand painting it would be your best bet
Honestly, the only thing I've ever trusted is professional printing. And one item really doesn't cost that much! Any printer (even an embroidery shop) should be able to run fabric with the proper tools and ink. The result is always sharper and longer-lasting than ANYTHING you could do at home. I know it's probably not the answer you wanted, but I'd dish out the $10-ish bucks every time for a pro job. (And if in the future you ever want to wash your flightsuit, this method will stand up to endless washes.)
Staples prints t-shirts for about $10. Maybe you could take the cloth into your local branch and ask them about printing a unique garment? I know there are several specialized screen printing shops/embriodery kiosks in my area. Can't hurt to do a google search The pants look much better lengthwise, but you'll want to sew some spats if they start to bunch or bulge under the armor. At least now you're not tripping on them!
The "ears" on the helmet look like they'll be really cool.I gotta admit though, part of me is a little sad that you've decided not to go with the wolf on the bucket.I totally would have taken a picture with you of both of us in kit once we were both official. XD