The solution that worked for me was I shaved a little plastic off the back of Arcana's head. As in a hair-thin strip at the back. You can use a nail file but I only had a cutter on hand in the office.

Now the headmaster gimmick works perfectly -- the head goes all the way in and the lock holds it down (via Arcana's neck) and pressing the lock down releases the entire thing cleanly.

You guys were right -- it was the paint on the headmaster's head that's causing the problem.

 

I'm not seeing the "pushed too far" problem. I think people assume the lock is supposed to go In the slot on the back of the head, and that when it goes over it becomes an issue. But I think that's intention. I think the slot on the headmaster's head is just from the way it was molded. But I'm just guessing.

I think the main issue is the paint on the inside of the main body's neck port was not meant to be painted, or was painted to thick. The inconsistency of the paint is causing some with tightness and then some that seem fine

 

it's mostly the paint in the socket you put the headmaster in, and SOME minor manufacturing flaws with the head master's tiny head, just smooth those out a bit and it fits fine, and to remove him, just fold up the tech spec panel first, then hold it as you push the gray chest part down to release the head, and gently pull, if it doesn't come out easily, STOP.

 

The gap is supposed to be there.
It gives you space to oull the grey part down which would release the headmaster.(Of course the Headmaster gimmick isn't the best.)

So it's supposed to be there.

 

The only downsides are the frequently mentioned difficulty of getting the Headmaster (Arcana according to the TFWiki, but he's never named on the box) out of the body. The Headmaster pilot docks by sticking it's head into a socket in the top of Brainstorm's chest. The grey lever piece just above his canopy is supposed to be pushed down to eject the head, but mine is very tight and has to be removed carefully. The tip about pulling the Headmaster forward as you are ejecting it works well. I've never had Arcana's head come off in the socket yet, and I'm too chicken to sand down the sides of the pilot's head for fear or ruining it. The seat inside the cockpit is also supposed to be spring-loaded to fold down when you plug the head in to show tech specs like the G1 Headmasters, but mine flops down if you so much as breathe on it. The hands are a bit floppy where they fold into the arms for conversion. Not a big deal, though.

 

A drop or two of floor polish into the pin will tighten it up.

 

TFW2005.COM member Skyclaw points out that "Reprolabels has a great sticker placement for Brainstorm! Really dresses this guy up and makes him stand out!":

Reprolabels.com - Brainstorm (Generations)

EDIT THIS POST FOR TUTORIAL

Just got this guy. The head on Arcana is really loose as the right fist (oddly), but nothing I can't fix. Speaking of Arcana, it's a little weird with those gimpy arms, but it's cool we've gotten a Headmaster like this. Not gonna complain too much there. Overall, it's a pretty fantastic figure. I'd highly recommend it to anyone.



Thanks to the everyone who's contributed to the Generations Brainstorm fixes!