So I've got my kit all cut out, and I'm in the process of fine tuning and sizing. As I've said before, I'm looking to make it as accurate as I possibly can and go for the highest level, but honestly, I mostly just want a cool looking costume so I'm willing to sacrifice if it's not possible. My main concern now is that I'm 6'3" and 240lbs, so the pieces fit a bit snug so far. Some of them I might be able to get away with if I trim the return edge, but it looks like I might have to shim some of the pieces regardless.
So my question is what material should I use to make shims out of, and how close can I trim the return edge? I see people have suggested to use plastic signs and spray paint, but can that get the same glossy black? I'd rather have black plastic if possible so I don't have to worry about touching up paint. And are there places where the return edge is REQUIRED? I like the look of it, but I just know its going to rub and be uncomfortable in some places.
Also, I'm new here and dont know what the posting protocol is? I know how to search my question first, but is it ok to make a new post when I have a question, or should I make a dedicated "Build" thread and ask all my questions there? I don't really plan on documenting my build, but I want to follow the expected protocol so people don't hate me ;P