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1. To me, all the damage, the nicks, dings, scrapes and c-scar all suggest Vader surviving battles. Explosions, that put all the nicks and scrapes, the c-scar, perhaps weapons fire. All designed to add to the 'character' of this evil warrior. Why is there a 'black' tusk and a 'silver' tusk? Why not both black or both silver? Why...? Because He had to replace one in the field, and could not get an exact match. If, not..... then what types of incidents on set created these details? Exactly how did the helmet get all those nicks, scrapes and that c-scar? It is safe to say the most fragile portion of a Vader mask is the 'tubes', very few show no signs of damage and this helmet exhibits more damage after 2 months of shooting, than some of the 27 year old ROTJ helmets.
Come on man that's not investigative research it's pure supposition and opinion based on movie folklore, it's not grounded in reality at all.
You need to put all the story nonsense out of your mind and concentrate on looking at the visual evidence.
Are you seriously suggesting the prop department went to the lengths of duplicating exactly the smudge on the right cheek i circled before aswell as all the tiny flecks of black showing through the gunmetal on the left cheek that Sithlord highlighted ?
Never gonna happen, nobody is gonna go to that much trouble even if they could for a low budget time contstrained movie from the 70's, they wouldn't even go to that much bother now, why would they ?
Nobody is ever going to notice a black spec a fraction of a millimetre in size while watching a movie and that's what the studio is making remember a movie not a study article for prop fans and computer geeks, time is money why would a studio spend money on something the paying audience is never going to notice unless they freeze frame and take HD screen grabs ?
Lets look objectively at your reasoning, it seems unless i've missed something your opinion is based on.
1) You can't see where the C-scar is on the DC shot.
2) The helmet and masks looks cleaner and shinier.
3) The tusk has more black on it.
Those to me seem to be the three actual physical points you raised if i'm correct.
1) You don't see the c-scar, i can't speak for others but i certainly can see where it is but even so it's been shown in other shots that depending on the angle and lighting the c-scar is visible and then not in the very same shot and just by a slight movement of the head it vanishes.
2) The helmet looks cleaner, of course it does these are earlier shots i dunno why this is so implausible ?
Have you looked at and seen actual movie props ? they aren't treated with kid gloves between takes or during.
We're not talking about $100k dollars worth of fibreglass and paint here, as long as it looks reasonable on screen to the viewer nobody cares about the odd ding or scratch, nobody watching the film is going to notice or care.
3) same as obove.
Sorry but from what i see you're focusing far less on the actual visual evidence and far more on the pardon the pun obsession with battle damage which to me holds less water than a tin bucket that's been peppered with two dozen shotgun blasts.
We all know Lucas made up stuff as he was going along through all the movies, you think he had Luke and Leia dabble with the subject of incest intentionaly in his family friendly space adventure movie ?
That's taking family friendly a bit too far don't ya think ?
And why is Vader in this big battle anyway and what battle is it ?
We don't see Anakin getting into trouble too much in any of the earlier movies or any of the other Jedi either, not in any physical fights so to speak anyway, they just cut people down and deflect blasts with their sabers ?
What suddenly Vader can't be bothered with deflecting blasts now he just lets them hit him, by the way Hans blaster didn't seem to harm his glove at all in ESB did it ?
And why don't we actually ever see Vader in any battles in any of the movies ?
Right at the start of ANH we se him wait and let the troopers mop up the rebels before he makes his entrance, he's not leading from the front or doing any fighting at all.
The same with the Hoth battle in ESB and again the Endor battle in ROTJ.
That's precisely how military works the officers give the orders and the grunts do the fighting.
There is and never was battle damage it's just retcon to keep the geeks who ask questions at sci-fi cons happy with an explanation.
P.S try KMplayer for screengrabs, it's freeware and will save grabs in bitmap,jpg or png format.