So I had this leg harness that I commissioned from this local armourer last year. He had made me a prototype of the leg harness made in aircraft aluminum, which looked decent. I then told him it wouldn't suit me for what I was doing with Live steel and said to make it with mild steel.

I went over to his place and to see what progress he had made and it wasn't what I was expecting. I had told him it was decent, only to not hurt the guys feelings. It wasn't completed and He told me I could take it with me to get some second opinions. I later had bought GDFB leg harnesses, which were not only cheaper then his price but better looking and fitted me much better. So I kinda went with that route and had put aside/forgot about getting back with the guy about not wanting his leg harness he had made. All I ever did with it was put it on once and showed some friends to hear their thoughts. It's been a year since then and I wanna return the leg harness and not have there be any bad blood. I was willing to give him $100 for his time he put into it...but not sure how to approach him about it.

Well my friend,it looks like you really are in a pickle :\ :surprised: It sounds like you made an agreement with this craftsman for a finished product.It seems awfully rude to back out now.
If you really must though,you know the old saying.....honesty is the best policy.Just tell him how much you appreciate his work,but that the product simply wasn't what you had originally envisioned.He should be able to understand that this sometimes happens in any line of specialized work.

Of course,if you really think he'll be hurt, just don't return it.A lousy $100 isn't worth losing a relationship. :)