I realize this is probably going to come off as a bit silly, but in Iron Man II how could James Rhodes easily don the Mark II armor that was designed to fit Tony Stark? As you can see in this image (which isn't an "in universe" shot) Tony and Rhodey are roughly the same height, but it appears that Rhodey has a smaller frame than Tony, which would seem to make for an ill fit of the armor, especially for flight.
This issue could of course have been addressed by the Air Force during the retrofit with Justin Hammer.
Answer
All the scenes of Tony donning armor involve considerable mechanical adjustment to fit Tony's frame. From a control systems perspective, the best way to do that is via feedback (e.g. tighten boots until they exert a certain amount of pressure).
Thus, as long as Rhodey was vaguely close to Tony's size, the suit should have just fit--maybe not as well as it fit Tony, but still quite well (unless Tony built it with truly tiny tolerances, which is probably inadvisable if he ever wanted to wear it after e.g. eating a large meal). A smart suit would also notice that its auto-fitting was out of its normal parameters and--if it hadn't already--would presumably perform additional identity checks, so this answer doesn't contradict the "Rhodey was supposed to take it" answers.
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