So heavy yet it really just looks so good. I was sooo happy with the outcome and now that I FINALLY figured out the clasping system, it is practically perfect. I had a lot of problem like I mentioned earlier with the scale and how the Galactic Armory files are put together. Really, that guy should try printing his own models out and wear them.
Essential 3D edits - I widened the arm wholes ALOT. I also had some regrets later after I printed it that I didn't widen it enough so I used boiling hot water to deform the chest plate to widen them a bit more. I wanted to reduce how my biceps rubbed on the side. Now it all fits very comfortably. But my advice to anyone else...go even wider on the arm holes. Just go all the way. The Halo 1-3 armor had it right. I also added the 117 number directly to the armor itself in a nice 3D bevel. It
Clasping system - I first went with a magnet and velcro combination. That sucked. Then I went with a stronger velcro and no magnet...that sucked even more. Then I went FULL MAGNET, and now when I put the pieces together it makes a satisfying CLUNK sound and it feels like I am almost welded into the suit. I should never have doubted your advice Rock Lobbster!
Cooling System - The cooling system rocks, and I am about to add a few more tweaks, like sealing in the intake section to the vents outside. I have it all connected to a 10,000ma battery...which I think will last me around 11+hours of the fans on full blast. And the fans are not loud at all. It just adds a slight hum to my armor which is probably cool to people outside.
Padding - I used the padding that came with my 3D printer to pad the neck and shoulders of the armor. It reallly reallly really helps. It is an essential upgrade. I also added some high density foam to peak out on either side of the shoulders. It looks great and it also serves the purpose of hiding the clasp for the shoulder pad armor and creates a buffer for them too. It is SO nice.
TIP - Don't do what I did and make the 3D print super thick and tough. Unless you are like going to fight a person with a baseball bat or something...you just don't need the torso to be that tough.
Closeup of the fans. The intake are the holes I drilled in the intake fins on the back.