Shawn, looks like you are quite a veteran in this sort of thing. The only real one I have done was a bit of a nightmare. I was contracted to do a character for an event. The head of it according to the drawing was a meter in diameter, so I reduced it to 75 cm, I had one and a half days to design build and deliver it. I worked to 4am and got it together, and on delivery found they had given me the wrong body size of the actors, they had a few petty corrections and insisted on zip closures etc. They had already dropped the price down to half what they had offered me to get me interested, the accountant asked for a further discount which I refused (as I was fuming by now) I had to catch a taxi home, add extra body length, put zip in, change teeth, new cape,etc, and have it delivered just before performance. The whole thing put me off doing more jobs. found a pic of it...
