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Here is Scott's answer to my question (or actually design via Scott):
2. Lich Leech: Sky High, Sea Hawk and a few others have very bulky armor at the sides, giving them an overstuffed look that detracts from their appearance (they look awesome otherwise). It appears to be a problem with putting the connectors at the sides and under the arms, making the armor much thicker there than anywhere else, which in turn makes the arms stick out and gives the figures an overstuffed appearance. Any thoughts on keeping the armor slimmer in the future, especially under the arms?
Designed asked to pass this along directly:
• We have started moving armor tabs further back in order to not add the extra wall thickness to the silhouette
• The last couple of figures have been full bodied armor which means the extra wall thickness runs all the way down to the waist, not half like- Too Bad, King Grayskull, Sky high so they don't seem as wide
First point sounds good, I'm not sure I understand what they're getting at in the second point. Two Bad and KG have no armor at all in the effected area, but Sky High has very thick armor directly under his arms and is one of the problem figures. What am I missing?