That forcepike looks awesome! nicely done!

The order, as already said is not set in stone. What helped my decide what order to do things in was how I was going to acquire my helmet.

If you are going to get a finished product, ready to wear out of the box (these are not as common as the raw buckets), then what you would want to do is start ...

My build is made of DistinctiveFabric's velveteen. Machine-washable and the color is awesome. The one beef I have with it is that it is kinda stiff, and doesn't drape as well as velvet would.

That second mock-up looks much better! I'm not an expert in ROTJ though, so take it with a pinch of salt.

With the lining and outer shell, I didn't have to pad it to get the imposing shoulder. Velvet and Velveteen are pretty thick materials.

Those look good, the only cause for concern that I could see wouldl be zipper (if there is one) placement. Zippers should be on the inside of the calf. It clearly isn't there in the picture, so if the zipper is in the back than they probably won't fly.

Buuuut, the boot is fully waterproof, which ...

Right, any printed thing is going to take smoothing. I'm looking specifically at shoulder-to-height ratio (which I now realize I should have specified, my bad). How you scale it doesn't affect the overall proportions of the helmet though.

Has anyone printed their helmet yet? I'd love to pm you and bounce some ideas off of you.

On a related note, is this helmet a good shape for a TFU Guard or ROTS guard? (Would it work for an AOTC guard?)

http://www.thingiverse.com/thing:349643

They also show up in the Wii version, according to the other thread. Does the Wii have enough res?

I would advise you to get samples of fabric from distinctivefabrics.com. I got my material(velveteen) from them and I loved the shade of the red. I bet the black will look awesome. I went with velveteen because theirs is machine-washable!