Chopper

Mr. Paul: https://www.mrpaulsshoretrooperbuild.co.uk/about/ Nico helmet: https://www.etsy.com/listing/864903122/rogue-one-shoretrooper-helmet

I can't totally see from the photos, but did you add the reinforcement strips on the inside of the helmet?

The neck seal is an optional accessory. It is not required for clearance. It looks like it should be fine, based on the photos. Neck Seal Black fabric only; no rubberized or leather parts. Trapunto-quilted ribbing. Conceals the entire neck. Must be worn under the collar of the undersuit. OPTIONAL Level two certification (if applicable): Neck seal has a velcro closure. Closure is no wider than .5 inches (12mm).

In the ear canal or over and obscuring the ear holes?

Agreed you want a glue that's specifically designed to bond plastic, not metal.

Yeah, E6000 will leave you with pieces of a helmet and that's not going to cut it. You need a permanent bond. I recommend Devcon Plastic Weld for securing the reinforcement strips. https://www.amazon.com/Devcon-22045-Plastic-Welder-Dev-Tube/dp/B003NUGL9S

Dennis is correct. You want a chemical bond that joins the reinforced plastic to the chest plate. A chemical bond, like with abs glue or plastic weld will have some flex. CA glue is strong but rigid and brittle. It does not "weld" the plastic reinforcement to the armor.

Yes, use a heat gun to heat the strips (away from the helmet), then once the straps are hot enough to be flexy, press them into place. Once they cool, they'll keep their shape and you can glue them in. You should have strips reinforcing along the entire seam line. There should be no gaps showing though, or else you risk seam cracking.

Did you keep the bits you trimmed? You're going to have to glue plastic bracing on the inside to support the helmet either way. Once you have the interior braces in place, you can make ABS paste out of the scrap plastic and fill in the gaps. Any other finishing can be done with spot putty. https://www.whitearmor.net/forum/topic/42866-how-to-make-abs-paste/

Yeah, keep in mind that that AI generated answers are not necessarily going to be accurate. Certainly not to the level of nuance that comes with some aspects of CRL interpretation. Glad you reached out.

The EFX helmet is approvable. For the Mando scout they used the EFX helmet on screen, so it's the most accurate for that particular costume. Most people don't tend to wear it due to limited availability and the fact that it's made of fiberglass and therefore heavier than the ABS helmets out there. It's also somewhat of a collectors item, so it seems to fetch a decent price on the secondary market.

The circle looking thing on the handle.

Put some adhesive backed black velcro on the capacitor part on the inside of the handle, and some white velcro on the inside of the holster. Also fairly easily removable if you want to ditch using it. Other people have used magnets, but that's a bit more involved.

Take a photo from the front, as I can't see the inside portion of the vest sleeve.

Ears look fine