Very nice...I am resurrecting my one...in 2003, I thought it would be a good idea to fill the body with expanding foam to reinforce it as the resin was quite thin. Phase one went OK and I left it for a couple of days to ensure that the foam was fully cured before slicing off the surplus and (very firmly) gluing the body base on....hmmmm....slight sequencing problem: should have sliced off the surplus and then left it for a few days to cure.
I was working away from home when my wife rang up and asked if that Star Wars thing in the garage was expensive as it had just exploded. The foam had reactivated on contact with the air when I sliced of the surplus foam and commenced expanding again when I secured the base - expanding a whole lot and with the base so well attached it squeezed out wherever there was a weakness. I was so gutted at the damage that i threw it in a box and only brought it out again after seeing your thread...
Damege was pretty bad as the expanding foam had warmed up and actually stretched the resin of the body sides out into a big bulge so it wasn't just a matter of warming it and straightening the bulge...have gotten it reasonably square now but have had to windlass the sides in using a massive woodscrew set into the foam as an anchor because no glue would stick any bracing to the resin.
Have now finshed the body and legs and am just dciding on a final pose before securing the 'toes' then it's off to work on the head and finally a Snow Speeder for it to step on...