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Boil and pop Han's head.
Helmet: cut off the head of a stormtrooper, at mid-chest (use this helmet).
Body: cut off helmet at the neck (this'll be the body).
Fashion helmet by dremmeling off anything that isn't part of the helmet.
Fashion body by add sculpty to create the "neck" (see $90 Luketrooper for model).
Stick headpost into sculpty, turn it a few times.
Boil (don't bake!) figure in hot water for 2-3 minutes until sculpty hardens.
Paint neck white to match trooper's body.
Add blaster and helmet-you can dremmel it down all you want, it probably still won't fit on his head.
Now, go kick some stormtrooper butt!
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