Thanks for the words of encouragement guys :mrgreen:
To answer your question Fizzle the expanding foam is pretty messy stuff, but it fills out the armor pretty well. They main drawback is that when it hardens it can expand the armor to the point of breaking some of the joins. (This happened to my first Chest Plate, much anger insued out of that one) But the 2nd attempt worked alot better, just had to be a bit more careful as to how much foam was used.
As for Red and Tac the first Boot I made was waaaay too large, I had to measure my foot and rescale it to match, with a bit of extra room for wearing suitable footwear inside the armor. After that I just used a measuring tape on the relevant body part and scaled the part on pepakura to match. Now both boots and Calves fit pretty well, and will fit even better once I put some foam into them.