My thoughts on "fixing" Falcon would have been going straight to the Night Force version. Make the black jacket/shirt plus the webbing and belt into a vest. It would remove the weird belt is molded on but the shoulder harness straps are both molded on but also loose. Also the black beret might have hidden the lack of detail better.
I would have just make a head with the beret molded on. Cheaper to do and also removes that weird big head problem.
Also would have made the pack radio removable. If not capable to insert inside a hole in the backpack, then have it snap into a gap. Then convert the combat knife on the pack into a machete. Add in a removeable knife, much smaller, on the "vest". I would have used real string to make a rope coil. Also make the canteens removable and snap on. Give him a pistol as a cross draw onto the "vest". That way purists can still have the legs mostly free of anything on them.
Also upgrade his guns. Give him a shotgun like the above. I recognize the line wants to avoid too many real looking weapons, because it's in brick and mortar stores and has to account for the "Soccer Mom" demographic who might buy these figures for kids ( But are they really? I still wager it's nearly all adults, that being said, I understand the desire to make all the weapons seem a little more fantasy/sci fi instead of hyper realistic)
Then give him his original shotgun as a smaller simple pistol gripped backup that could rigged somewhere onto the backpack.
A couple of "Bonus" items if they could fit it into the budget - A straightened "snake" like the one in the movie that pierced Duke's chest. Also a side bag, like the satchel that came with Tunnel Rat. That would have helped to remove the empty look around his legs area.
Finally, if they just couldn't get the headsculpt right, at least give him "lamp black" and give him a camo face as a tactical consideration, to help hide the atrocious lips and weird eyes, etc, etc. That would still fit the Night Force theme and add in a bit of a cool factor to the figure.
Put it this way. Classified Spirit is a damn sexy figure. When I saw it up close, I said to myself, "Damn, this is straight up awesome figure" When I think about Spirit, then see this Falcon now, it looks like two entirely different toy lines. It's like one guy is from Silverhawks and one guy is a Thundercat.
This is just bizarre, because I remember 4 inch Falcon as a kid, in the original RAH run, and EVERYONE wanted him. He was an awesome figure back then. And that wasn't just because of the hype added by the movie.
I bet you a million dollars right now that Gridiron Studios is going to build a "repair kit" for this figure. Probably adding in some of the tweaks I'm discussing now.
How do you blow a layup like this? This is like Derek Jeter deciding out of the blue to get married.