Bermans & Nathans took moulds from an ESB suit, and used them to create a vac-form buck to make new parts, due to this, the ROTJ armour's details are softer and less well-defined than ANH/ESB.This section is till work in progress as I'm awaiting screen caps.

Helmet

• For a more in-depth look at the helmet, visit Jez's excellent site StarWarshelmets

Shoulder Bells

• The shoulder bells on the ROTJ armour have a distinctive 'pinched' appearance, and they sit farther out when worn. The Trooper in the photo above shoulder bell looks thinner than normal.

Connection Bridges

• The Connection Bridges were for ROTJ is were made from vac-fomred vinyl and are used to hold both the front and back sections together, unlike the bridges in ANH and ESB which were decorative.
  

Chest Section

• The ROTJ Stormtrooper chest armour, back armour, ab-section/crotch and kidney plate/butt piece all had white edging trim along the edges.

AB plate Buttons

• The ab-plate button details are in a different layout than the ANH/ESB costumes, it's a J shape.

Hand Plates

• Clamshell type hand guards, same as Empire Strikes Back.

Kidney/Butt Section

• The kidney plate/butt plate were separate pieces on the ANH/ESB trooper suits, whereas they were combined to form one solid piece for ROTJ.

No covering plastic strips

• Also the way the biceps, forearms, thighs and shins were assembled differed between ANH/ESB and ROTJ. In the latter suits one half of the armour overlaps the other half front and back, on the earlier suits one half meets the other and the joins were then covered by separate plastic strips added on top. The exception being at the back of the shins which overlapped a little and could be opened up to allow the wearer to get them over his foot!
• If you look closely at a suit from ROTJ you can see the remnants of the edges of these separate plastic strips on the leading edges of the thighs, (they're tell tale signs reproduced from the original ESB/ANH suit).