I didn't have those problems with the figure but I remember that others did. Most of the figure is fine, though, so I would be happy with or without the tweaks.
True, they definitely need a new ROTS helmet. I spoke to Derryl about this at CVI, though I dunno if it will be changed. Also I've had no issues moving the AOTC helmets up slightly and having them look much better, but a spacer would be welcome too.
They could just use the head from the Endor Capture version so there would be no new tooling, though they would probably have to modify something to that it could sit a little better (the Endor Capture figure seems to have a shallower hole in his head).
I forgot about the issue on this one, but are the differences really that noticeable? The only thing I can see easily is the fact that the feet shouldn't have the claws in the back, but I can overlook that since it seems necessary to letting the figure stand at all. Wookieepedia's reference isn't very good on this one, so it's hard to tell - the droids are barely in the film anyway so I'm not too worried it.



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I haven't looked at the figure much lately, but I remember that people would put the figure's "mouth" underneath the head-wrap piece instead of over it -
it's going to be quicker and quicker. 
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