Kev & Nick sent us this info about another Anthony Daniels TV appearance where he talks about Threepio in Episode II and the rerelease of the Classic Trilogy on VHS. The report does contain minor spoilers, so skip the space below if you're avoiding them:

Interesting, this doesn't seem to fit with the quote from Ben Burtt when he says he put the faceplate on Daniels, and a Jay Laga'aia interview where he mentions that the suit "just fit" (see the report here. So, maybe he just didn't explain it clearly on the show.

If you can shed any more light on this, send us the information!