Darth Vader was one of the more difficult custom I've created.  Designed using Vader from the classic Unleashed toy line and a Robotic Spawn figure, I was able to craft what Vader might look like after a savage battle.  I wanted to create a Vader that was more evil then he appears in the movies. One that fraught along side his troops in battle and was menacing in his victories.  I felt that a more skeletal face expressed my idea better then if I had used the more gentle, "Old Man" like in the movie.

I started by cutting the Vader and Spawn figure into there base parts, head, arms, legs, torso.   I then played around with a combination of parts until I decided on the right arrangement.  Spawn's head, left arm, torso, right leg and left thigh.  Vader's helmet, left arm, right lower leg and armor. I then glued all the parts together and filled in any gaps with putty.  Vader's helmet needed to be cut in half, hollowed out in order to fit in his exposed head, then reassembled. The torn cloth on his legs were sculpted using putty, while his capes where taken from the various Spawn figures.