I get sick and stay off the forum a couple weeks, and come back to a bunch of progress

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Good call on the dickies over the suede; it'd probably be hot as hell, The faux fur looks like it'll be nice for a kama, and those gloves look like they'll match quite nicely. For the boots, if you're willing to attach the wraps directly, the taller boots would be perfect. You can glue the wraps right onto them and not have to worry about velcro or zippers or straps or whatever to fasten them in place.
For the bucket and shoulder, idk if you're familiar with XTC-3D, but it's a wonder for getting rid of print lines. It tends to fill in small details, but for something like your pieces it would be perfect, and save you a lot of sand and refill and sand again time. You do have to do more than one coat, usually, but it generally takes way fewer than bondo or other fillers, and as a resin, it ends up pretty rigid in the end. I would just advise mounting your visor first, so that the resin doesn't crack or warp if it cures out of position to where the helmet will be with the visor installed.