Well then, it sounds to me like you're glad you finally got one! They can be tricky to assemble, as you've already discovered, but if you take your time and remain patient, the payoff is well worth the effort.
Btw, did you use the hair dryer when putting him together? Heating up the chest armor can make it a lot easier getting it fitted around his torso, and if you open the clasp in the front, it's somewhat easier to get the back closed. I usually close the back first and the front last. Then I hit the whole thing all around with the hair dryer to get a nice snug, uniform fit around the torso. When it all cools down again, it's much less likely to pop open while you're posing him.