Right, head has been boiled, the neck plug and eye plate removed. I cut the eye plate right down, took the sides and bottom off, so fat jaw is solved.
The eye plate fits back nicely and will be repainted.
I'm experimenting with another option though, I found a couple of nuts in my tool box, they have nylon caps on top. I cut the caps off and after I tiny amount of dremel work they fit nicely (at least as well as hot toys pers), I'm also going to repaint these but they'll be held in with blu-tac, meaning I can change the direction in which they look.
I'll post pics of the w.i.p tomorrow.