Truth is, Hayden is about 6’1" & roughly the same height and build as Bob Anderson was. And they didn’t just throw the suit on him, he wore a padded undersuit as Don Bies commented on the Prop Replica Forum and there are scenes of him getting fitted in this padded undersuit on the EP3 docus. They actually reshot part of the scene with another actor back at ILM because George decided he didn’t want Vader’s wrists bound up to the sides of his head as seen in the EP3 teaser. In the other trailers and the movies his wrists are strapped at near waist level at his sides.
I’ve seen people complain about the shoulders and chestplate looking too wide in this ESB shot, which I thought could be Anderson, but everything I’ve read says it was Prowse. Notice the shoulder bells look fixed to the rest of it also this same ESB shot. http://caps.pictures/198/0-starwars5/full/star-wars5-movie-screencaps.com-13056.jpg
The chest box in itself in ROTS actually looked more like the ANH chestbox to me (the button shapes and such) than the ESB/ROTJ one. I’ve always thought it’s kind of silly to gripe about his suit changes, Vader has proven to change his suit, swapped out electronics and other cosmetics from ANH to ESB. Whether he wears the inner cloak over or under the armor has nothing to do with technology being advanced.
Chest Box comparison here. I realize there were diffences with the ESB and ROTJ boxes, but this is just an idea.
http://vignette3.wikia.nocookie.net/starwars/images/e/ed/Compspanels4wn.jpg/revision/latest?cb=20060321184821
WAAAAAAAAY better than ROTS! Thank goodness!
I don’t quite see the difference with ROTS for the suit. The helmet I get it, but the suit ?
Well, for one his body looks way to small for the armor. The chest box is attached to the leather suit with no straps (and once again has different button/light colors). The belt has some minor differences. The shoulder &a chest armor is an all new one-piece design that doesn’t look as cool and doesn’t allow him to actually raise his arms. It’s also much wider than Hayden’s actual shoulders in an attempt to give Vader the proper shape/size.
Over all the the ROTS suit is just a weird thing that doesn’t get the “feel” of the classic Vader suits thanks to a lot of the updates and modernizations. And it also has a weirdness from trying to make a person who’s clearly too small fill out a larger person’s armor.