Gridiron has yet to do plate carriers but, it appears they're heading in that direction with the belt & shoulder holster they're now offering. Better yet, just buy the Action Force plate carriers as they're really nice and durable. To me, I prefer web gear like the one Falcon comes with. Though, I'd probably cut off and glue the shirt portion on his belt. So stupid of Hasbro to not make that piece separate and keyed into the hip area.
There's already a number of 3D printing stores that make replacement heads for LT. Falcon. Anthanatos Limited which is on Etsy & Ebay has a really nice one with options for the beret (part of the head & proper scale or, with the beret removeable and a little large):
But I would like one I don't have to paint (I'm still going to try my hand at painting the Anthanatos head with beret sculpted on). A lot of people are using the Action Force Blowback head to replace the Hasbro Falcon one, you do need some sticky tack or hot glue to set it on the Classified neck ball joint I believe, I don't own a Falcon yet.