I wish to clarify my statement - armor should still be of the highest quality. I make no exceptions when I say that even Pepakura-based armor should be able to pass the test. However, like I said. Micron-accurate armor is a ways off for almost everyone here, unless you're Legendary Armor and have a wallet the size of George Bush's luck, and unfortunately a lot of the processes involved in making such accurate pieces are just too far out of the budget range for a lot of people here.
Nobody can rightfully expect a new 405th recruit of, say, 18-20 years of age, to be able to spend over $1000 on getting a moulded, fitted armor set. It's just not possible - a lot of these people need to pay off college, or find somewhere to live, and if my own personal experience is anything to look at, paying to live is rather expensive. A hobby like this just has no place in the finance department, and once you do the math, saving up for a set of armor to be made for you is just not viable.
So, we have wonderful people like Robogenisis and Flying_Squirl who are willing to put the time into making decently-detailed files that people can print and use to form a base for their armor. And a lot of the armors I've seen based on Pepakura are very promising.
That's not to say that we should instantly accept Pepakura as a solid base for armor-making. In fact, I'm quite the opposite. As a base for moulding, Pepakura is almost perfect, but I'd hardly call it suitable if a person were to make a full suit from it and use that suit time and again. It's not durable enough and the benefits of using it are very limited outside of it being cheap and easy to construct. In short - Pepakura is fine for one convention, maybe two if it's detailed and strengthened suitably, but any time after that the user should seriously consider casting out of plastic.
Hence my statement regarding improvement. All armor starts somewhere, be it from a Pepakura-based set or a straight moulding of the set from clay. But as a group, the 405th simply cannot afford to take a stance and say 'armor must be micron-accurate and if it isn't, look elsewhere'. Not in its infancy - such a stance will undoubtedly drive away members. Wait until we have a dedicated set of users who have moulded, high-quality armors, and wait until the organisation has established itself. Then the 405th will be able to afford itself the luxury of denying lesser-quality armor (and by this, I mean 'anything less than movie-accurate sets).
Put simply: taking up the stance of 'perfect or get out' at this early stage will be incredibly damaging. Believe me, I wish for everyone to be able to have high-quality armor, but the simple fact is that there are decent people out there who want to take part, but are excluded because they don't have the means and/or funding to do so.