Thanks guys. I have enjoyed discussing Vader and especially the helmet over the years on several forums, but I still seek out advise and assistance from people who know more than me, because sometimes you can go blind focusing on something and then an extra set of eyes can be of great help. Honestly, I have gotten so much help with these I can't thank everybody enough. Incidentally, even people who haven't studied Vader as much can be an eye opener as they can sometimes shake up in-grown ideas that turn out to be wrong.
I won't do the molding and casting myself. The current plan is to offer the parts raw, as it may be too much for my producer to paint them as well. Also, because these will not be prepared for HT or Sideshow bodies. I own neither and it would mean more work than I'm willing to put into this. Everyone will have to do that work on their own. I know it may dissuade some from buying these, but I have to prioritize my time and effort to what I initially created these for - the statues I'm still working on. The armor kits was just a kind of afterthought, since I had already scanned it, and people might be interested in it for their HT or Sideshow mods - but this will be for skilled modelers.
Aww man, Paul, I was really looking forward to seeing your WIP's progress. I really think you should continue working on them and perfecting them, if nothing else then for the satisfaction of completing them... and you will lean a lot by working on them you may not learn from working with the casts from me.