These look fantastic DJ! Perfectly good use of that old cast...

This side shot is my favourite.

What did you mean by curled in?

Oh - on the Rick Baker mold, the rubber was a little dried out and bent or "curled" in on Vader's right side. Imagine a rubber mat put against a wall. If you hold it against the wall by putting your hands in the middle, the top of it will curl down, away from the wall perhaps. That was the case with that area. You can see it in the ESB promo mask and a couple other Vaders out there. It seems to have been tended to on the SL by simply tacking that part of the mold back to its edges, etc.

Does that make sense?

I think so, so you had to either push the rubber back, or the mask already had the warping so had to be adjusted with filler etc.

Also how have you mounted the dome? Photo's would be helpful.

It looks like the dome is sitting slightly too high.

Oh it's just the basic black plastic tubing for mounting. Nothing out of the ordinary. But I looked at all sorts of dome placement from both ESB and ROTJ and chose that "look." There are some Vader domes I found that sit even slightly higher so it is kind of a middle ground.