Harmy, the Vader shot looks pretty good, definitely the best I have seen attempts to composite the original pieces in there.

I don't know if you are open to suggestions on it but one thing I would do is just re-colour the eyes using the 2004 footage. Its very easy to change brown to blue just using something like After Effects (which, I know, you don't like). That way, you would only have to composite the eyebrow piece. It would look much better, and probably be invisible. If you think this will be too much work then thats fine, the version as is looks pretty good, but even on Youtube I can see the quality difference and some of the seams, because the focal point of the shot is the mans eyes, which are from a different source. That example tends to draw a lot of attention to the OOT-area, unfortunately, so leaving the eye footage as is and just changing the colour would definitely make it less noticeable.