That sounds like a good idea having one or 2 permanent scars on Sam's face (either that or he privately got plastic surgery/laser removal ).
And concerning what I meant by the scars being visible from torn clothing, it was actually a bit from your idea in one of the updates you have listed. No matter where Sam is shot, there will be small (but noticeable) taring of clothes. But the more Sam is (or whoever the main character is) shot in that same area of his body during that level, the wider that specific area of clothing gets torn. And if the wide rippings of clothing is torn in an area of Sam's body where he happens to have scars from previous SC's, then it will be shown.
But his clothing will be changed each level. Or even better, give the gamer the option to change Sam's clothing each mission.
Let me know what you think
I appreciate your ideas for campaigning modes. And I'm a bit curious, but could you explain a little more about what your ideas about the new objectives/FAN objectives are?