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So the shins are split into four parts which I glued together and then the usual fill and sand. 
The plan is that you have two real parts that are connected via magnets to help when fitting. I have done this but not sure it that's tright for the static suit but my thoughts are that if I want to ever use it then its done right.

here are some pictures of fitment and the painting process

[Image: attachment.php?aid=1391]

After some filling
[Image: attachment.php?aid=1392]

First coat of colour (yeah wife wasn't happy me using her broom)
[Image: attachment.php?aid=1393]

Final colour coat before clear. (sorry about the crap picture will try again when it cools down)
[Image: attachment.php?aid=1394]

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Interesting to read, even I will not build something like this.
What I wonder is, what post-processing did you do after printing and before spraying paint on it?
In the red, the layers are barely visible.
My printer is set to medium level which has been good enough for finishing. I use Primer filler and car putty to fill any issues, holes or welds and then a lot of sanding and then multiple coats of primer filler between sands. I use 180 grit sand paper for general and then 800 for the top layers before sanding. The paint colour I do one coat dry and two coats wet and then two wet coats of clear for protection.

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