I'm sure that between Skull myself and the rest of the Chunky Mafia we can see you on the right roads to Chunky fulfillment.
The ratchets can get loose with age so the best thing to do is to check tightness of screws etc don't go mad as they can de-thread the plastic if you go ape tight. if it is still floppy you can cut up a small bit on really thin cardboard to put behind the spring to give it more compression, this will in turn make the joint tighter. Sloppy side to side stuff mostly found on boots or KO's can be remedied with small washers to pack out the joint, although the knee joints are slightly more possable when sloppy .
Any questions just ask between us all theres not much we haven't done or know about.
And welcome to the Board and the Chunky Monkeys.
P.S I will be doing some more to my (over a year now) work in progress Chunky.