Place the Han Solo head on the Biggs body using the boil-and-pop method.

Step 2

Completely Sculpey a helmet onto the Han head. use as may reference source as possible to get accurate details.

Step 3

Cut off the radio pack on the chest and sculpt on a new vest and radio pack. Use movie stills from  http://www.theforce.net/ excellent multimedia vault. Kenner's version was completely inaccurate so this is entirely made from sculpey.

Step 4

Reference the Art of Return of the Jedi, page 111, for the radio pack and bib on the chest. These are just preliminary sketches for the movie, but make excellent reference for sculpting.

Step 5

On both figs Sculpey boot leggings since these are clear in the ROTJ briefing shots.

Step 6

Add a couple of straps on the leg straps of your Awing pilot from sculpey.

Step 7

Paint your pilot. Use straight colors brushed on to make him look like a toy still. The A-wing pack is painted just like the helmet: first a coat of green-gray. Then dry brush lighter and lighter until a final drybrushing of white.

Step 8

Then paint the trim around where it meets the face black. Also paint some helmet markings with a red-brown to match the movie stills on the lower part of the helmet on both sides.

Step 9

Then add a couple of aluminum dabs of paint to make it look the paint is chipped on the helmet and a couple of details are finished in black and white.

Step 10

As a final touch, paint rigging string, black tread and fine black modeling tubing is used for the chest-radio packs to finish the figs.

Recipe provided by: Roger Wilsdorf's Homepage Roger Wilsdorf