.. Speaking of helms for Chaos and LSM. I've had a problem from the get go as far as the scale or proportion of our helmets, in relation to the actual size of the Astartes head. I feel our helms are way too small proportionately, and they'd NEVER fit over a proper sized Astartes head. The pic comparison below says it all. The head is as large, if not larger than, the helmet. I.e. Our helmets in game would NEVER fit over a properly proportioned Astartes cranium. If/when we ever see 'no helm' look in game, it will be abundantly clear that our helmets are all too small, or the heads are too small, or both. ..
I'd say this one is up to some serious debate; there's a ton of official art around where we can see that SM's body proportions are not like normal humans' and indeed their heads appear rather small sitting atop of those super-pumped 3-meter-tall uber-Schwarzenegger bodies. Sits fine with me.
It's a thing that happens, but it's not common. What happens is when a Chaos Champion becomes favored enough, fulfills some prophecy, spends WAY too long in the Eye of Terror, etc his armor will begin to fuse to his skin. This is not an always complete process as the armor digs into the flesh and begins to meld but the Chaos Marine can still take it off if he's willing to rip off that strip of skin in the process. It might stall at that or it might become more integrated, this could actually take a very long time however(For example Marduk of the Word Bearers didn't significantly experience this symptom until a whole ten thousand years after the Siege of Terra.) the only place where this more common then not is with obliterators, mutilators, and possessed marines whose armor, or even weapons can fuse into their bodies. Argal Tal couldn't remove his plating nor could his brothers, but even then exceptions may be made. It's a sign of favor basically, for it to actually transpire the marine in question has to actually attract the gods attention. If all marines could do that it would actually be brokenly strong, as often it eliminates the need for scavenging and repair as the suit just draws from the host like an organ.
I have read about that somewhere either possessed, thoese with much favor or thoese who are in the warp too much have it fuse and "become alive in cases"I know legions like alpha and iron warriors have some amount the least amount of mutation taint because, alpha wants their geenseed to stay pure while iron warriors believe it as a sign of weakness. Personally I wouldn't want to be stuck in my armor for eternity who knows mabey some marines from the heresy want their ways to remain the same before the damnation begun and others embraced it as we all have seen.