In regards to the heads, we selected a bunch of different heads and they were shipped to me. I would put the heads on different bodies, take pictures and upload them for the group. As a team we would discus which head worked, which didn't and then put it to a vote.
Take Down was always suppose to be a "tough as nails" drill instructor. When we were looking at the possible head options the one with the cap was one of the original ones we were looking at. If I recall correctly it was the original pick but when we received the sample heads that one was missed in the order. We had a time table so went with the best looking one we had.I still think he's bass ass looking.
His arms there was a lot of concern over the dye job coming through the paint job over time. I painted two coats of flesh coloured paint and then sealed it. The dye didn't bleed through the paint job but at the time we didn't know for sure.
Also, I think on the prototype the entire body was dyed red and on the finished product I think the legs were dyed black.
Prototype Coyote Trooper's head he does look meaner on the released head. Interesting note, I have never seen that head anywhere else. The other heads I've seen on line but not that one.
The Night Ops dude there really wasn't a huge difference. It's just silver paint an the shade of grey was a little different. The lighter shade of grey one the one released matched better to the rest of the grey on the figure.