Here's some info about what I believe the origin of AA's current run of helmets come from. This information comes first hand from conversations I've had with AA via phone.
After ANH was finished, AA had nothing but 'skins' left. Skins meaning unused left over vac formed pieces from the original production. He then set out to alter the helmet molds to make them more "production friendly".
I'm talking about the 5 piece helmet design with the serrated hose section in the rear, and the hero faceplate with the lack of undercut. Some of you have seen them.
Ainsworth said that he was improving on the design, asthetically as well as from a production standpoint. He thought that LFL would come back to him for the sequel so he wanted to be prepared. Because of the film's success, and because he was paid so little for his items from the first film, he felt entitled to a major payday for the sequel. When they didn't, he felt slighted which is why he has such issues with LFL. This was long before the lawsuit.
Some of these style of helmets were put it on Christie's along with some other items. They were there to raise capital for his new business as well as guage market value and demand for a new production of helmets.
Anyways, I believe wholeheartedly (as do a lot of other top trooper helmet enthusiasts) that his current run of trooper helmets were derived from molds of the 'improved design' helmet. It is believed that he took those molds, and tried his best to restore them to the way they looked for the original film helmets, but was not very successful. Thus all the differences between his current helmets and the original ones.
One look at the 'improved design' helmets and the current ones and you can clearly see that one was derived from the other.
I used to think that it was a possibility that he had the ORIGINAL molds and altered them, but I don't believe that could be a possibility anymore. Just new molds made from the new version helmets made post production.
Also, based on real evidence that hasn't been made public yet, it is clear that AA did not sculpt the helmet. Beyond the shadow of a doubt.
I spoke to him too. And a lot more recently than you did. By skins he meant the armor, not the helmet. I'm sure you've seen the recent photo of the skins he was referring to. And I showed in another AA thread that it's not possible for the SDS stunts to have come from the improved design helmet...with comparisons. So I'm not sure why you dig up that theory over and over again. The interior of the low numbered SDS (I have #12) stunts have details seen on the originals...on their interiors. I showed that as well. The TIE face has the indentations between the teeth, just like the original TIE helmet. How do you explain those similarities? And he never felt slighted as you put it expecting a major payday for the sequel because he didn't provide any helmet for the sequels, did he. As you know, they just reused helmets for ESB and remolded for ROTJ. You paint him as if he's did the runs to get back at LFL and that's simply not the case. Maybe that's how you would react personally if you were in his position. He was ENCOURAGED to start the business by people like you when you heard he had the original molds. And you always have a habit of bolstering your theories with "everyone else agrees with me". Well I'm sure everyone else can voice their own opinions and don't need you to be their spokesperson.
Brian Muir was the only accredited sculptor on ANH. Liz Moore did C3PO and then left the production to go work with her husband on another film. Brian finished up C3PO and did the Vader and TK armor but didn't know who did the TK helmet. Don't forget there was no design for the front of the TIE, AA solved that problem by using the TK face for the TIE. So then where did these LFL photos of a sculpted TK come from? If they were from January 1976 that's really early on and then the question is do those molds actually look like a TK helmet? According to AA, the mold is the sculpture.
One thing about the LFL photos is where they were taken...that's my question. Could they have been taken in the USA? GL was not too involved in the design process in the UK...that fell to John Barry, the production designer. He was the one providing the sketched interpretations of the McQuarrie paintings to people like Muir and AA. So if this so called stormtrooper helmet sculpture existed, what was it based on? And why was it made so early on? AA claims his design of the helmet wasn't based on the McQuarrie but on insects and such. Brian Muir had just a small sketch for his inspiration of the Darth Vader mask and helmet which is why it looks different than the McQuarrie.
People tend to jump ahead here on the issues and until we see those photos LFL has of the TK helmet sculpt and find out who did it and what it was based on and whether it's even the mold that was used to make the original TK helmets, there are still a lot we don't know about this case. But if the photos are genuine, AA is in a pickle. But regardless of how the case works out or how expensive his helmets are, he did produce the original helmets and armor for ANH. He was probably given molds of the sculpt by the art department and he made his own positive and modified that to the point where he thinks it's his own artistic contribution. That's been my impression up to this point. So what he told me and what Brian Muir told me has some thread of consistency. It boils down merely to the interpretation of how AA views his modifications, if any, to the helmet design. According to him there were modifications to the armor which was sculpted by Brian Muir. However, according to Brian, the armor we see onscreen is exactly as he sculpted it. I haven't seen the LFL photos yet but I'm sure we'll see them soon enough.
I'm not defending AA now, although I spent a heck of a lot of time and effort in the past doing so giving him the benefit of the doubt. But my interest was always in getting the facts and making rational deductions on what his contribution might have been. The bottom line is if you buy an SDS helmet you are buying one made by the original maker at the original shop using the original methods he used back then (but not HDPE). Are they from the original molds? Well that depends on how you define original. I've had discussions about the original Vader molds on forums and people still often misinterpret what an original mold is. For example, if there was a clay TK head sculpt and the plasterers made a mold of that for AA, and he took that mold to make a master positive that he modified...that to him is the original mold, even though there was a clay sculpt and there was a mold for that. But this is the same situation as in the case of the Darth Vader helmet. There was a clay sculpt, a mold taken of that and then an intermediate step and after that another mold...so the screen ANH helmets didn't actually come from the original mold as people here always interpret. What needs to be clarified is what AA got from the art department, if anything. According to him he made the helmet mold from scratch but there was a sculpt of some kind. But there was also a prototype Vader helmet at ILM that was never used in the production. Maybe someone here already saw the TK helmet sculpt photos and knows the answer.