Where does he get those wonderful toys?

I'm assuming that most anyone who would be reading this is familiar with my weekly photo comic, Minions at Work. MaW is created (mostly, some occasional photo manipulation is used to) using 1/6th scale action figures, sets, and props.

The other day, I got this note from Minions reader Phil M.:

I love your comics. I was wondering, where did you find all the scaled down items? most of them look like the correct scale for the "minion" you have. I have never seen trash cans, golf carts, etc.
Just wondering...

Fair, question, but one I figured only a fraction of Minions readers would be interested in. So rather than cluttering up their space with what would have to be a lengthy post, I decided to answer over here, at my seldom-used hobby blog, where it was more likely to be seen by interested parties (and where interested Minions readers would be able to find it).

So, just for starters, let's take a look at the latest cartoon (you can, by the way, click on any of these to view a larger version):


Okay, the pat answer to Phil's question is, "everywhere." I've spent several years obsessively building up huge collection of figures, set-pieces, props, and accessories. Some are made. Some are found as action figure or doll accessories. Some come from the most unlikely places.

So what I'm going to do is use some cartoons as examples, talk about where the various items in them came from, and use that to offer more general advice about where you might find things of your own.

Let's just kind of go left to right and discuss things as we find them.

Number Two is talking on a pretty nice phone. The phone is a modified kitchen magnet I found at a kitchen store. I had to do some cutting and modification to make the hand-set removable.

Since the set is non-magnetic, I stuck it to the wall temporarily using a putty-like reusable adhesive clay sold for mounting posters and the like. You can find it in most any office supply stuff, and it's good for a million and one things when making dioramas. It doesn't dry out, so I keep blobs of it stuck to the side of a cabinet adjacent to my "Minions" workbench/studio, ready for immediate use. Like I said, it's reusable, so when I pull down the blob holding the phone to the wall, it will go back up there for reuse.

In the foreground there are some sandbags. Those are accessories that come with "Power Team" military action figure play-sets. Since most of my Minions use Power Team bodies, I've bought a lot of those over the years. The bags are actually hollow plastic, and open on the back, and so only look good from the front. I almost threw them away at some point, but I'm glad I didn't.

Not only are they handy for giving a set that pseudo-military "lair" look, but the hollow backside is great for hiding battery-powered LED "puck" lights, which I often use to as blue fill-lights in my photo set-ups. Actually, there's a light hidden there, but I forgot to turn it on before shooting. Whoops.

The rats fighting on top of the bags are toy-store items, sold as part of line of clear plastic tubes carrying various plastic animals. Some tubes are sold with nothing but various colored rubber rats, and I've bought a bunch of these. Again, handy around the lair, and I use mostly the black ones, which most of the rats in the tubes are white or tan. Save those for the lab-scenes.

The broken table and green storage drum are also Power Team items. The table isn't broken. It just snapped together in the first place, so I just snapped it back apart to make it appear smashed. It will be good as new next time I need it.

You can't see it well here, but the cell door is scratch-built. It's made from foam core, cardstock, toothpicks (for bars in the window), craft store hinges, and a padlock-charm found in a bead store.

1/6th scale doors are hard to come by, and I should make some more in various styles.

The wooden crates were found in thrift stores. Crates like these are used as containers for gift-soaps, bath products, little jars of jelly and jam, and other such things. I think the fad for these may be over, but there are still zillions of them cluttering up grandma closets everywhere.

The trash cans also came from thrift stores. They're at once surprisingly common, and hard to find. They're made as promotional items and sold to garbage and recycling companies, usually imprinted with their logos. The idea is you use them for pencil cups, paper clips, and the company's number is on your desk next time you need trash service. I've managed to pick up maybe half-a-dozen different ones in various colors. I don't know ANY place to pick these up at retail, but if you really want one, calling up the various trash companies in your area might turn one up. Good luck explaining WHY you want it.

Okay, let's move onto another prop-intensive cartoon.


Phil mentioned the Minionmobile, so I had to include it. The Minionmobile is obviously a golf cart. It was sold as part of some die-cast vehicle line a few years back, and it's actually more like 1/8th scale, not 1/6th. The roof was way too low for a 1/6th figure, so I had to extend the metal rods that support the roof and raise the seat to allow for more leg-room. You can see details on how I did it here. It doesn't look bad, and actually, I think the "clown car" aspect adds a subtle bit of humor everywhere it appears.

The clips in the back are designed to hold golf bags, which were missing on my example of the golf cart (I saw it in stores, but mine came from a thrift store again). So, instead, we have a GI Joe anti-tank missile launcher back there, and a scuba tank from an 18" knock-off action figure sold at Wal-Mart a few years back. (I bought some on clearance with idea of making giants or monsters out of them.)

While this golf-cart may be hard to find (check eBay), there are alternatives. Wal-Mart sold an RC Yamaha Rhino 4-wheel ATV last year, and there's a golf cart in the current "High School Musical" fashion-doll line that has possibilities.

The traffic cones are Power Team items again, and I wish I had more of them. They're great little props.

The high-tech curbs are rails from an Imaginex building set I think. More thrift store finds. The nukes are actually launchers from a Quest Aerospace Micromax model rocket starter set. I bought a bunch of these on clearance a few years back, mainly for the rockets and motors. The launchers I didn't have much use for, until I noticed how much they did look like some kind of nuclear storage canister or warhead. Now they show up regularly in Minions at Work sets.

Now onto something that shows a whole variety of prop-sources:


Going left to right again:
The wonderful console is part of a "Muppets in Space" action figure playset from a few years back. I got a bunch of these very cheap on clearance, and they're just full of great parts and set pieces. The console was plenty big enough, but it was too low, so it's removed from its original base and mounted on an inverted plastic cup sold as a desk organizer.

You can see the edge of an arched doorway in the back. This is actually one of those "sold on TV" gizmos called a "Can-A-Round." They're white plastic tracks designed to allow you to slide cans of soda and beer around to the back of your fridge. Or something. Seems like a stupid idea to me, but when painted gray, they look like high-tech girders and bulkheads. I have two or three sets, and I use them all the time.

The back wall is foam-core board (office supply or craft store) painted silver. It's decorated with PVC plastic pipe from the hardware store, held on with metal clips, screws, and nuts, also purchased there. The louvered vents are sold as under-eave vents for home roofs. Lots of goodies can be found in the hardware store, if you browse everywhere, and thing of things in terms of form, not intended function.

The equipment rack in the background is another one of those wooden gift crates I mentioned earlier. I painted it black, and stuffed it with a variety of military field radios (Hasbro GI Joe, Power Team, 21st Century toys), again, repainted and detailed using hardware spray paints and craft acrylic paint.

The chairs are all fashion doll items. Fashion doll lines are good sources for furniture and household items, though they often need repainting (lots of pink). Barbie, Bratz and My Scene lines are all good sources of stuff.

The table is thrown together. The top is just a piece of scrap wood put in as packing material in an "assemble it yourself" bookcase I bought a while back. The pedestal bases are a couple of curtain hardware things I spotted at the thrift store (form, not function, again). The top is held on with more of that poster putty stuff.

The top of the podium is a doll-house item. Standard doll-houses are 1/12th scale, half the size of 1/6th, but a lot of usable items can be found at doll-house suppliers. This was a desk-top lectern though, so I had to build the base myself, using wood scraps, and decorative molding strip (hardware store). Craft paint tied it all together.

The map and stand are from a Power Team set again, as is the green crate.

The briefcase actually was sold as a novelty gift item. It has a manicure set inside! But the latches, handle, and all the hardware work fine, and it's in pretty good scale. I've also seen these sold as business card holders. Business and desk-top novelty items and premiums often yield interesting items. In addition to the trash cans and briefcases, I've also picked up some cool office chairs, beach chairs, desktop computers, and other goodies sold as novelty or promotional goods.

The red table is another wooden crate. The yellow thing on top is part of some toddler playset. I found it at a thrift store, liked the shape, and made a few modifications to the "screen" on the side, replacing animal stickers with green cardstock (so I can easily Photoshop in computer displays or whatever).

The phone is our magnet again from the first cartoon. I've got a lot of novelty magnets that are useful props: computers, desk phones, pay phones, blenders, coffee-makers, dustbusters, clothes irons, toasters, lunchboxes, crates of fruit, pots and pans, toaster ovens, microwave ovens, aquariums, lunchboxes, gumball machines, wine bottles, all sorts of stuff. It pays to spin through the kitchen store every once in a while.

Okay, one more, in part to see how the same props get used again and again in different ways. This is Cap'n Rehab's submarine.



The porthole in the background is some kind of fiberboard ring I found in the floral section of a craft store. I have no idea what it's used for. I spay painted it gray, put in some scrapbook paper for the "reef scene" outside, and stuck it to the wall with more putty.

The ship's wheel was a wall hanging I bought at a tourist-trap gift store (I live in a beach town). The metal base for it (which you can't see) was made from a brass candle holder and some copper-pipe fittings from the hardware store.

In the foreground, there's the Muppet's in Space console again. Behind Number 9, you can see one of those rocket-launcher "nukes" again. The red barrel is a repainted Power Team item. The lamp thingies on top is actually an old, novelty salt-and-pepper set. I think I got it for $2 at a junk shop.

The arched doorway is made from our friend the Can-A-Round again. The door in the middle is cardboard and some textured scrapbooking paper I got at a craft store.

The high-tech crates came with figures in the GI Joe "Sigma Six" line.

The rubber duck around Cap'n Rehab's neck was part of a set of novelty earrings I spotted while following my wife into an accessory store at the mall. (Really guys, if your wife or girlfriend is at all crafty, it pays to follow her into bead, craft, and fabric stores now and then. You can go in by yourself, but the strange women who work in these places seem to have a talent for asking embarrassing questions.)

The little Nautilus desk model in the foreground was an accessory for a smaller scale Captain Nemo action figure I bought on deep clearance a while back. (I had no interest in the figure, but he came with a ton of cool accessories. I've also seen cool, usable for 1/6th accessories in other small-scale figures. Wrestling figures, the entire Muppets line being examples. (I got a cool mop and janitor's rolling bucket, a footlocker, some books, and food items with Muppets figures.) But for things like desk models, look for smaller die-cast toys. Nothing spruces up a military office like a model fighter plane, missile, or tank on the desk, and they're all over the die-cast section of the toy store. I've also found similar things in gumball machines and museum gift-shops.

I could keep doing this, but this post has gotten pretty long already. General hints:

Develop a "one-sixth eye." Develop the habit of looking at things in scale. Potential props are everywhere. For instance, I noticed one day while taking the protective cap off a "sports bottle" style bottle of drinking water I got at the theater, that it looked like a miniature Tupperware style bowl. I collected a few and added them to my box of kitchen and food items.

For specific ready-made 1/6th items, check fashion doll toy lines, but also look for novelty items elsewhere, sold as novelty clocks, souvenirs, key-chains, lighters, pencil sharpeners, magnets, desk accessories, business give-aways, jewelry, charms, etc. In addition to toy and hobby stores, you should also be browsing craft stores, bead stores (lots of interesting charms, bits of metal hardware, clasps, etc.), kitchen stores (especially for magnets and other novelty items), gift stores, souvenir stores (in my experience, the junkier the better), museum gift shops, zoo gift shops, and office supply stores.

Finally, you'll notice that a lot of my stuff comes from thrift stores. Thrift stores, garage sales, junk-stores, swap meets, rummage sales, are full of useful prop items. Just use the 1/6th eye. A wooden jewelry box is a desk. A pencil cup is a waste basket. A novelty metal cocktail skewer or letter-opener is a sword.

This stuff is literally everywhere, and often the coolest items are cheap or free. It's all a matter of having the eye, and the creativity, to find them.

Thinking inside the Box

After doing over 125 "Minions at Work" photo cartoons, I'm getting a little bored. Not with the Minions but with the sets I photograph them on.

My "stage" for the Minions is nothing but a small workbench on which I throw together sets using a variety of backdrops and walls (most built of foamcore board) and a variety of other "wild" set pieces, such as columns, beams, arches, and doorways. I can really do a wide variety of sets by swapping my basic pieces around, but for the most part, they have one thing in common. They're flat.

Because of the single-panel format for "Minions at Work," it's generally important to see all the characters in a scene clearly: who they are, what they're doing, what their body language is, and what they're holding. That's hard to do when you get more than two characters in a scene, especially if you're also struggling to get an interesting angle on the set (something else my current setup makes difficult).

Somebody is always turned the wrong way, or you can't see their hands when you need to, or you can't see what they're holding, or where they're looking, or something else that's important to the scene or the joke.

But it's also difficult to make multi-level sets to my requirement. I need modular flexibility. I need things that are sturdy and versatile. I need things that are self-supporting and that don't eat up too much of my limited (especially front-to-back) bench space. And most of all, I need cheap.

Here's a solution I've come up with (click on any of the images for larger versions):


Yeah, boxes. These are recycled "shoebox" sized Express Mail boxes. I've just glued the flaps shut and covered them with self-adhesive shelf-paper, also known as contact paper.

Contact paper is wonderful stuff, with all sorts of uses. It's cheap, comes in useful sizes, sticks well to most surfaces without additional glue or tape, and can be used to disguise or repurpose all sorts of common objects for use in our 1/6th world.

The big problem is the limited patterns available and their applicability to 1/6th sets. A lot of the patterns are florals or other decorative patterns that aren't much use to me, and there are wood-grain patterns that are way out of scale for 1/6th use.

On the other hand, there are sold colors, geometric patterns (like black and white or other checks, good for floor coverings, and stripes, which have some uses), and metallic. Here's an on-line-site to show you some of the patterns and colors you may also find in your local stores.


I've used the metallic papers before, but for this project, I went with a couple of stone patterns, one a gray granite and another a gray marble.

Why two patterns? Well, while either pattern can be used for both walls and floors, it's my feeling that the coarse pattern of the granite is better for floors, and the smoother pattern of the marble is better for walls.

Also, cover a box with one pattern, and it still looks rather like a box. But if the sides are one pattern, and the top another, then it takes on a bit more weight and reality.

But remember, I said flexible, and that's where I got sneaky. The trick her is that, in a photo, normally you can only see at most three of the six sides of a box. If you see an exposed side with one pattern, you'll tend to assume that the reverse face of the box is the same, but it doesn't have to be.

So for my boxes, I covered the ends, one wide side, and one narrow side with marble, and one wide side and one narrow side with granite. By flipping and rotating the boxes to expose various combination of surfaces, two little boxes can be used for an awful lot of different things.

Let's start with something simple. Stood on ends, the boxes become modular, free-standing wall panels. These can be used to provide a stub wall in the foreground of a picture, or to suggest a doorway or hall where none actually exists. Turn them one way, and you've got granite walls.

Turn them the other way, and you've got marble.

One thing to remember for photo purposes is, it isn't important what you build, it's what people see, and what they fill in mentally to complete the picture.

So while we can see this is just a couple of boxes on end, if you were to zoom in or crop to eliminate the tops of the boxes, the viewer will just assume it's a wall that extends all the way to some invisible ceiling. Same with the sizes. If the picture doesn't show the end of the wall, the viewer will assume it continues well beyond the picture, even if the wall overhangs the frame by a fraction of an inch.

Of course, I've only got two boxes, so the wall is necessarily pretty small. Making two more would allow for much more sizable walls, and the flexibility to create a doorway in the middle.

But while this is useful, my primary purpose for creating these was to create some verticality to my sets. Let's see how that works...

Here, by flopping the boxes on their side, I create a raised walkway or second level along the back of the set. This isn't a full "story" bump by any means, but it's enough to allow background characters to be seen clearly over foreground ones, and it adds some visual interest.

Note that I've put the granite "walkway" side on top, and the marble on the front. The fact that the floor is also covered with granite pattern ties the set together.

This setup would also work as a large display shelf of some sort, like a museum or trade show-exhibit, or a runway for a fashion show or a strip club. These things are just as flexible as your imagination.

In a perfect world, the gap between the two boxes wouldn't be dead center in the shot, but it's easy to hide behind an object or character, or to Photoshop out. You could also use a scrap of the same pattern contact paper to cover the gap. Or, you could just live with it, and assume it's a natural seam in the stonework.

Okay, here we flip the boxes, and we have a higher, narrower walkway. Still not a full story, but enough to provide some real separation between the levels.

Okay, the next step to tie these things into a scene is to enhance them with props. I happen to have three of these Power Team traffic barriers, so I'll put them on top of the box walkway. Now it looks more like a balcony or catwalk of some sort.

Of course, you may not have something ready made like this. One thing to remember is that cardboard is really easy to work with. You could punch or drill some evenly spaced holes and make removable stanchions out of wooden dowels or tubing. (Remember though, any holes you make in a side may limit its usability as a wall for later use) Connect the stanchions with scale-sized-ropes or small chain (check the jewelry department at craft stores) and you've got hand-rails.

Now, let's get a little more creative in both our arrangements of the boxes, and the use of props.

In this example, by flipping the boxes in two different directions, and careful exposure of a bit of that granite pattern, we've got a wall with a set-back shelf that we can fill with decorative props.

This somehow reminds me of Stargate SG-1 and the interior of a Goa'uld mother-ship. Once again a longer wall would be better, and you could also add to the height by stacking more boxes on top.

(Most of the Egyptian props, by the way, were purchased in the aquarium department of a pet store. The gong is a brass nick-nack I picked up at a thrift store.)

This arrangement suggests the base of a massive column, perhaps along the side of a great temple or hall. Once again, I've arranged the boxes to create a shelf, and added another aquarium department prop to sell it.

A row of two or three of these would be even more effective in suggesting a large and impressive space. As I said before, let their imaginations work for you. Show them three, and they'll imagine a dozen.

This scene would also be greatly improved by a backdrop more in keeping with the foreground (it could just be a sheet of foamcore covered with more marble paper, and some decorations added, like hanging tapestries created from cheap scarves or from scrapbook papers purchased in a craft store.

Finally, here's a slight variation on the above arrangement, used to create an impressive platform from which an Evil Overlord can address their attentive Minions. The custom-built lectern that I've built from wood and molding scraps is a big plus, but you could simply provide a box of roughly the same proportions (perhaps also disguised with shelf paper) for them to stand behind.

This scene would be greatly improved by hanging something on the backdrop, such as a flag, banner, shield, or logo.

Ironically, my first use of these in Minions at Work really doesn't fit any of the above. Mostly they're used to support a pre-existing set piece, my metal catwalk prop. Here's the cartoon. If you're interested in seeing how the catwalk was built (it's an easily reproducable design from parts you can get in most home-centers or hardware stores), you'll find a post on it here.

Of course, while the granite and marble patterns work well for me in a lot of applications, they won't work everywhere, or for everything. If you don't find the pattern you need in contact paper, check the fancy papers sold by the sheet in the scrapbook section of most craft stores. Paper can be glued to the box or applied with double-sided tape. You can even create your own papers by taking photos (culled form the net or shot with your own camera) and printing them on a color printer (heavier paper stock is easier to work with than standard printing paper). Using your own camera, you can capture weathered wood, cracked concrete, stone, rock tile, rusted metal, or whatever else you need, and scale it for use in 1/6th (or other scale) scenes.

New Bright CXT Truck

I found one of these monsters, trashed out and no remote, at the Goodwill yesterday for $3.99. Despite a little flack from my wife, I couldn't pass on it. As big as it is, it's 1/10th scale or smaller, and the cab (even if the door opened) is way too small for a Joe. Maybe if you wanted a Sigma 6 semi, this would be just about right. I think this came with a dump bed, but it was broken off this one, as were many of the grab bars, and the steps on the driver side.
What really interested me is the chassis and the wheels. It's BIG. The wheels are 6 inches in diameter (with duals on the back). It's 29 inches long (14 feet 6 inches in Joe scale) and 14 inches across (seven feet scale), which gives it a bigger footprint than the New Bright H2, and it's taller. They learned their lesson with the H2. It's very light for its size. The motor is also small too though, which makes me wonder how much power it has, even with a 19.2v battery.
Operationally, it's a bust. It came with a battery, but I don't have a charger for the 19.2v batteries. But more importantly, no remote, and since it has a multi-band switch, I'm guessing it won't work with the New Bright 49mhz remote that I already have (it IS 49 mhz, so there's a slight possibility that it might work on one switch position, but not the others). I hate to invest $20 in another battery and remote (if I can find one) if my remote isn't going to work, and I can't test it without a charged battery.

My thought is to strip the body and use the chassis for some project. But if I want it motorized, I may have to install a completely new RC system (and I'd probably go to standard RC-type batteries too).

Here are some pictures, with a Soldiers of the World Jeep and some Joes for size reference.


The underside. The battery compartment looks almost identical to those with a snap-in 9.6v battery. The batteries do have the same footprint, but the 19.2v battery has slightly different contacts and flanges so you don't accidentally get them mixed up, and the 19.2v battery is twice as thick. Note that while it looks like there's tons of ground clearance, the front end and gearbox are still pretty low to the ground.


Note that the truck looks plenty tall, but when you compare Joe to the tiny doors, you seek the scale doesn't work at all


It's not tons longer than the Jeep, but it's wider.

Star Wars Helmet Tutorial

I'm not hugely into 1/6th Star Wars figures. I have a few, but not many. But I know there are tons of Star Wars fans, collectors, and customizers out there, so I'm passing along a couple methods of producing removable helmets for Empire troops.



The first is pretty straight-forward. The starting point in this case is a Hasbro TIE fighter pilot, though this technique would probably work for other Hasbro troops such as the storm-trooper, sand-trooper, clone-trooper, and maybe even Boba Fett or Darth Vader.

The figure shown is in fact just a thrift-store special I found nude. As you can see, the Hasbro TIE pilot is mounted on one of those awful Action Man/Hall of Fame bodies. I don't much like the proportions on these, or the lack of articulation (especially the lack of ankle rotation and head tilt).



One option on improving one of these figures is simply to remove the head and transplant it to a GI Joe body of your choice. The head-posts are completely compatible. Of course, you still have to contend with transplanting the molded glove-hands and the sewn-on costumes, but it's doable. But you're still stuck with a non-removable helmet, and that bothers me. Besides, maybe you just want a helmet to sit on a shelf or table in a diorama. So lets turn that TIE fighter "head" into a helmet.

First step is to remove the head. I used the "boil and pop" method. Dip the head into a pot of boiling water to soften the rubber, the pry it gently off the neck post. A narrow tool like a small screwdriver is very helpful in this task.

Take great cautions not to scald yourself, as the hot water likes to find its way inside the hollow head and cavities of the bodies and arms, then dribble out on you as you're working on the figure.

Here's the bottom of the removed head. You can see the opening for the figure's neck post. You can also see a ridge around the bottom of the helmet that probably represents where the real helmet ended. I chose to use that as my cut line. I've heard of people using Dremel moto-tools to cut these, but that's huge overkill. The head is soft vinyl and not very thick. I used a brand-new hobby-knife blade, and it cut like butter.

Again, use caution not to slip and cut yourself, or to cut too far into the helmet. Slow and gentle pressure is the way to go.

Here's the bottom of the helmet. The opening is plenty big for almost any kind of 1/6th figure head.

Here's the finished helmet shown on a molded-shirt CC-Joe with a WW2 head. If anything, this helmet is over-sized.

Our next project is much more challenging. Our starting point is a Burger-King kid's meal toy. These were out a year or two ago, and they aren't hard to find on eBay, or for that matter, at thrift stores and garage sales. There are a couple other figures in this line that might also provide useful helmets (I think there was a Clone Trooper and a Boba Fett, for instance).

The toy is a solid molded figure held together with those damned security screws (triangular openings in the head) that are on so many fast-food toys. (If anyone knows a source for an affordable driver to fit these, please tell me about it.) There's a light mechanism inside activated with a button on the backpack.

Since the helmet is molded as part of the whole, the first challenge is to cut it off. This would be MUCH easier if you could take the figure apart first, but lacking the right tool, and not wanting to take the time to try and drill the screws out, I just started cutting.

A Dremel tool probably would be useful here, but I don't use mine much, and I wasn't confident I could avoid cutting too much, especially in the complex little curves around the "jaw" of the helmet. So I opted for one of my favorite tools, a razor saw. I just took a lot of time and patience going round and round the helmet, coming at the joint line from all angles and taking away a bit of plastic at a time. It was tricky, but I got it done.

Here's the bottom after I cut it off. First problem, the neck opening is way too small. Second problem, the head is full of STUFF, including the LED light and battery holder. I used small needle-nosed pliers to break the tabs holding the light in and removed it. I then was able to work a small pair of diagonal-cutting pliers inside from the bottom and cut the post that contained the screw. This weakened it enough I was able to rip the two halves apart. Again, the right tool for the job would have made this so much easier.

Here are the two halves of the helmet. All the interior junk needs to go. I attacked it using two different sizes of diagonal cutters to "nibble" plastic interior parts out, and a pair of needle-nosed pliers to grab, twist, and break off what was left. Again, patience is required. Again, a Dremel tool would be an option, but be careful not to cut or grind through the outside shell.

Here's what I was left with. A Dremel probably would be the best way to enlarge the bottom opening, but I just sort of whittled things out using a sharp hobby knife, taking away the plastic a sliver at a time. Though I removed all the alignment pins, there's a lip around the edge that makes it easy to put back together properly. I glued the halves together with a bead of super-glue.

Here's the finished helmet on a CC Joe. This is a much tighter fit than the TIE helmet, but I had no trouble getting it on the Joe, and even got it on a much larger Power Team head. I think this is rather close to scale, actually. At least it looks right to me.

The nice thing about this is the you can care up plenty of extra Storm Trooper helmets, if you want them for custom projects or to make a squad of troops. Of course, you'll need to come up with armor for them. Since the original 1:1 Storm Trooper armor was made from vacuum-formed plastic sheet, and home vacuum-forming isn't difficult at all, it wouldn't be that hard for somebody to create some molds to mass-produce 1/6th Storm Trooper armor. Combine that with some simple black body suits, and you could crank out 1/6th Storm Troopers by the dozens!

Go on! I dare you! (And send me a set of armor when you're through.)