Sinestro
Sinestro is a figure that I've always wanted.  Frankly, I can't figure out why Kenner never made him in the first place.  He is Green Lantern's arch enemy after all.  I built him on a Green Lantern base with a Joker head.  First, I boiled and popped Joker's head onto Lantern's body.  Then, using my Dremel, I ground off the detail on Lantern's shoulders and the tops of his boots. I then carved off all of Joker's hair, while preserving his ears. I also carved off Jokers big grin, while leaving the chin intact.  I then used a lump of Sculpey and formed Sinestro's high forehead and his pointy hairline.  The tricky part was sculpting Sinestro's mouth area with Sculpey.  I used Lex Luthor's mouth as a reference, since he has the same sneer that I was going for with Sinestro. I also used Sculpey to augment Joker's nose, which was a bit too small to look right after the mouth resculpt.  Using Sculpey, I built Sinestro's gaunlets, belt, and boot tops.  I also used Sculpey to fill in the curved indentations under Lantern's arms.  After priming, I used a pencil to sketch the lines of the design on Sinestro's shirt.  Finally, I painted and sealed the figure.