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Got more time to sit down with Moon Studio's Dark Night. I guess it's really only the panels in the arm that were too tight because after working them a little bit and moving on to transforming the rest of the figure the tolerances aren't too bad.
It's a panel heavy transformation but it's not the hardest panelformer in the world, you really want some kind of nylon spudger to make splitting panels apart easier though. If you can do Roadking you can do this guy. The only time where it starts getting hard/annoying is when you're finishing up both legs because the way the clearances work out you just end up with less room the closer you are to completing them. A few parts are tricky but not that bad: There's a very specific way you have to move his shoulder joints when you're passing the arms to the top of his torso without scraping them against the plastic (also helps to do that with the chest panel undone). Same goes for that tiny little panel at the back of his feet. Considering the combiners weight will be resting on the edges of those panels I think it would be a really bad idea to try loosening any of them up. And the instructions don't show it but the outer side of his upper arm that the panel kibble attaches to can be lifted out purely for the purpose of creating clearance to bend his elbow joints to transform him, takes kind of a lot of force to do it the first time though. Don't blame anyone for not being able to find that considering how hard it is to move at first.
It's a pretty solid and good feeling robot and train once you're all set up though. I'm pretty confident that the ankle joint is strong enough for everything too, though I'm not sure about the attachment point for the knee, I'm hoping it's more than just that one square slot and it makes use of the other nearby peg holes as well.
Really the only problem I have with Dark Night is the painted undersides of his feet. They really should have sprung for some beige plastic instead of paint there.