Here's some early shots of my reworking of the shoulder pads. I was really happy that there was a seam on top of the shoulder to work from, so split them there and then cut away the folded over material to get an even edge.
I cut some small strips of thermal plastic sheet (goes very softer under a few seconds of a heat gun, but very firm normally) to add a joining piece and a shoulder sleeve/cup. I wanted to make these shoulder pads a lot more solid and less flexible. The sheet was double sided taped together and test fitted/heat treated dozens of times before I got the shaping I was happy with. Then I took them off and flattened them out on another sheet (not with heat, by hand) to trace the shapes so I then had the other sides pieces. This wasn't a lot of fun trying to get things even, and I'm sure more engineering oriented brains could've made it more accurate faster, but I'm happy it was only an afternoon's work to get the pieces done.
Next step was to blend and fill, I used an epoxy putty that dries very hard for this job and smoothed over the spots where it joined and then sanded to hide the join.
The shape is now a lot closer to the original piece, next is to cover the top layer with some textured self adhesive plastic to provide an even finish before painting/weathering. I decided to use pinheads for the silver dots on either side of the lacing and there's a few other minor details I'll add.
I'm still currently experimenting making my own feathers, the first method I tried ended up too bulky but I have another one to try today that I'm reasonably confident will work.
I've also redone the hair (poked some more in, trimmed, coloured), really happy with how thats looking, will post some photos later today.