One week update! its been a week since I've started this journey and I think I have some good progress to share. First, I'd like to talk about the things I've learned:
1. I have done some smaller prints on my printer, and I'm still getting good shells, but I am getting some warping on corners. To fix this, I am going to decrease my print bed temp 5 degrees until I find a good temp where the warping stops.
2. Filament matters. In the past I have used Inland filament that can be picked up at my local Micro Center. Its fine for low support structures, but I would recomend spending the few extra bucks for a better supported filament (HatchBox, Fillamentory, Rigid.Ink). Also, the more mainstream fillaments make taking the support structures off easier and lose less of the details.
Though I have had some issues with warping i have been able to fix most of the issues with my assembly adhesive, E-6000. E-6000 has proven to keep the bonds very well, and is also great for filling in any gaps. It will make sanding a bit longer; but in my mind, its a good trade off for a strong bond between the pieces. Any left over residue will likely come off during the priming process.
I have 11 pieces and clip left to complete the BR, lets hope I can fix some of the issues before getting to the Armor!
(I also need a better place to take pictures)