Hey all-
I will get back to addressing questions shortly, but I wanted to address Luke's point about using the real materials. Because there's a part of me that agrees with him. And believe me, we went down this road internally.
One could assume that if a person is willing and able to shell out $300 (or more) for a replica, said person would recognize that it's not a "toy," and that it's intended ot be treated as such. This means, most likely you put it under glass (or acrylic case) and treat it like a museum quality piece. (i.e. you don't touch it.)
This creates several issues, from a company's standpoint. First and foremost, we cannot assume that Joe Consumer is going to act a certain way. We can include all the "this is not a toy" documentation that we want, but people are going to do, what people are going to do.
Say for instance we made Gonzo accurately... the nose was extremely fragile. If you picked him up by the nose -- or say, were recreating the elevator scene from TGMC -- there's a chance (a very good chance) that the nose would tear right off his face. And I guarantee that we would have a minimum of five people do this in the first week! If I've learned anything from MR, it's that I will never stop being shocked at what people do with (and to) their high end collectibles! So in a sense, we need to cater to the lowest common denominator.
Couple that with the fact that the Photo Puppets -- more than any product this company has ever made -- demand to be played with. They are built with armatures, to be posed, and in a sense, their very nature works contrary to the idea of a museum quality replica. Take a lightsaber hilt. No moving parts; no fun. But these guys cry out to be man-handled. And therefore, they need to be durable.
Remember Ken's never-ending battle to balance between accurate sculpt and articulation? Well, mine is a battle between accuracy and durability.
But in terms of protecting the company from a barage of returned noseless Gonzos, it was determined early on that the foam would not work. (Plus, even if Joe Consumer did treat it properly, in two years, if the tip crumbled off, I assure you they would want their money back.)
Hope this helps some...
T