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I let the party know, in character, at the start of every mission immediately after or before the opening box text. It saves a ton of confusion when I shift personalities mid-session. Because if we're being honest, having a whole new person try and slip into the group would set off some "This person is going to betray us" flags if they weren't suspending disbelief for the sake of cooperative play.
I too am approaching the "Tony Stark" method of play, but it's mostly due to mechanics: Social Grace boosts my Sense Motive, which is really helpful to Snake Style, and I already have Disguise boosted to help with keeping things hush hush. I'm likely going to take Bluff or Intimidate as well, in order to help my Feinting and Enforcer tactics.
So far, though, not much thought has been given to the identity on the part of the table as a whole. I show up, introduce myself, and much like everyone else we focus mostly on finishing the mission in the allotted time slot. Roleplay for roleplay's sake has always has trouble fitting into 'traditional' PFS scenarios, so I'm basically playing a Dexterity Monk with no alignment restrictions and decent Charisma.
