I got into a fun argument with Gino over Star Wars last year at a Comic-Con party, he knows his stuff.

As for the Stunt vs Hero molds, I think you're mistaken about them being directly from the same tooling, the case against Ainsworth says that they kept only the stunt molds, and have been passing off reworked stunt molds as being from the hero tooling which they didn't have in their possession. Also, you yourself make the point that the stunt looks different from the hero due to physical differences like the mouth, and the gray trapezoid above the brow being further forward on the hero.