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1. The cable tube for pulling the faceplate up has too many curves in it, as well as lifting against gravity, compounded by pulling on the hinge from too far back in the helmet. All these things led to the servo being unable to lift the faceplate, even though it can lower it perfectly well.
2. To solve the problem, the cable tube was removed. Instead, I have placed an aluminium plate inside the helmet. The pull-cable will now be routed through steel eyelets screwed into the helmet and plate, right at the tip. This will achieve superior mechanical advantage to pull the faceplate up.
Trial and error is making the inside of the helmet look messy, but it will all be cleaned up and then lined when it's working properly.
3. To ensure the back, ribs and abdominal armour retain the correct size and shape while the slush-cast is poured inside, I test fit it over my waist, marked the contact points then wired it in place. Braces inside maintain shape while the resin cures and hardens.
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