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Same here. I've been unable to wrap my mind around the process and how it seems nearly identical to the 70's. You would think some kind of automation would have eliminated a few of these steps.
Economics... They can either:
Build a custom machine designed to properly pickup, orient and attach Mego sized heads of various sizes and shapes onto 3-5 different body types = $$$$$$ ?
Or
Pay someone in China $0.80 - $1.20 per hour to do it.
I think the issue of the belts riding so high goes back to the overly tight stringing of the bodies. After swapping out my FTC Riddler, I noticed that not only are the arms pulled into the torso, but the torso is pulled into the pelvis. Thus the "waistline" of the figure was non-existent. That's where the belt would normally rest on a Mego figure.
I tried swapping out the belts on Batman and Riddler FTC bodies and the purple belt rode high on Batman as well.
I don't think the issue is with the body, I think it's with the suit. If you feel the suit it pokes out where the shorts are stitched on, and I think that's causing the suit to push out enough to stop the belt. If you look at Riddler his suit is sleek and the belt seems to ride a little lower. And from the look of that picture, the 66 suit pushes out at the top of the shorts where they are stitched to the torso.
Looks like FTC is using a belt the same length as the original Mego belts but they changed the stitching to make it so the belt rides too high.
Overall these look great, but it Looks like the 66 Batman belts are riding high, too.
Hope they also make the 66 emblems part of the suit. Other than the belts riding too high so far the clothes have been just stellar on all these figures.
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