Cool! I've never used black worbla before so this is very interesting looks like the surface is a lot less grittier than original Worbla.
As for your air pockets (LARGE warts ;D haha) mine did the exact same thing (ty for pics! very helpful!!). If I can remember correctly, when working with mine, this is unavoidable -- only way to fix it is to work with it as you go. Since Worbla hardens quickly you need to work fast, but for preventing large bubbles, you need to work slowly (of course it would be like this -- can't be TOO easy. Thanks Murphy's Law!).
From what I remember, after initially forming the chest piece, any larger bubbles left I heated up (that specific area - so not the whole thing) and massaged it out by poking several small holes up and along the bubble. For example, you make a hole at the bottom, middle, and top of the bubble and gently press out the air up to each hole and proceed to the next one (this will also help prevent wrinkling that would occur by just making, say, one hole in your large bubble).
Omgosh lol "I"ve added pep files as one of the 18 layers of chinese hell". I need to remember to use this one in the future haha Very descriptive and also VERY accurate!! I've only ever worked with one pep file before (my Revan mask) so I can't enlighten you much on that ): suffice to say there are lots of options out there -- one way or another your hand-made Revan CAN get done but you've gotta decide how much literal blood, sweat, and tears you want to put into it I give you TONS of credit though for trying something relatively complicated so new to the game and I think you're doing a fantastic job thus far with work and research! Just remember: cosplaying is about fun! If you suddenly feel like making this costume has become a chore and the world is darker don't worry about buying pieces instead of making them. The end result is making people happy at troops and yourself happy by becoming a sweet ass character and hanging with friends - so in the and, where yes making a costume is awesome, buying one (or parts of one) is just as OK!! Cosplay is cosplay regardless of made or bought
Yes! Even if your Revan isn't 100% of what you want it to be (I know mine isn't -- I abhor my cloak and hood bahaha) it's that initial costume to get you into the Legion THEEEEN you can start getting serious! > my current build (will be second costume in Legion) is taking me a year total to make but damn will it be glorious. Let the first costume be the ride to get you there then you can either upgrade Revan or make/buy/modify another costume!!
and yeah Worbla does kill your fingers ... I've gotten well used to the pain by now haha