Emrys said:
The small "S" isn't the issue. It's the total package. The smaller S works on those 70s and 80s Superman comic drawings because overall, the body is simply large enough to accomodate it adequately. That and the flow of the cape around a more open collar helps the suit.
I made these manips to demonstrate that I mean. It's the entire composition of various elements of the suit that is the issue.
A dark style SR suit on Chris Reeve.
Chris's size and appearance just completely dominates the small S and even major flaws like the tight collar or smaller trunks. It still looks ridiculous by creating a very long torso and erasing any strength lines from the neck and shoulder-blades... but it can be done. However, on Routh, these elements only serve to accentuate Routh's "swimmer" profile and thin neck and makes him look weaker by comparision.
I made this manip awhile back to see how the suit looks without Routh and what improvements could me made. Look how simple it is. I think adjusting for most classic elements could help Routh look more powerful in the suit. By making the trunks higher and dropping the collar and allowing the cape to flow over the shoulders has the effect of compressing the chest and enhancing the triangle delta-shape torso (paralled with the inner triangle of the larger S shield) associated with strength. It's like wearing stripes to make you look taller/thinner. Same thing.