Commissioner Gordon
I decided to make a Commissioner Gordon since Kenner doesn't appear to be in any hurry to make him. For this figure, I used a B&RA Machine Gun Joker body and legs and the head and arms from a Men In Black Street-Stalkin' Kay.
First, I had to remove the head and arms from the Joker and Kay figures. I used the old "boil-n-pop" method for this. I also removed the lower part of the Joker body's trenchcoat. I then had to pop open the Joker torso to put the new arms in - I used a couple of screwdrivers to pry it apart. Be very careful when doing this! It's easy to stab yourself or someone nearby if you aren't careful. Once I had the Kay arms put on, I glued the torso halves back together.
Next, I used my Dremel to remove some of the details from the Joker torso chest area, mainly the shirt, tie, and inner jacket details between the two sides of the trenchcoat. Once that was done, I sculpted a smooth "shirt" over that, as well as a belt and necktie. I also sculpted a slight hair change and a mustache onto the Kay head and cured all pieces by boiling.
Putting the head on the torso was a bit of an adventure. Because the Joker has such a thin neck, doing a head swap with the existing neck pegs wasn't an option. Also, the Kay head won't fit flushly on the Joker torso without some modification. So I used my Dremel to remove some plastic from the neck and lower back of the head. I checked as I went to make sure I wasn't removing too much. Once it fit into place, I glued it on. It's no movable, but it fits now!
The Kay arms are good, except that his left hand is holding some futuristic sci-fi weapon (maybe the "noisy cricket?"). I cut that hand off at the cuff and replaced it with the left hand from a Batman Forever Two-Face. Much more police-like. Then I glued the lower half of the trenchcoat back on.
From there, all I had to do was paint him. The hardest part of this was doing the glasses and eyes. I painted the lenses flesh with a light wash of white, then went around the edges with black to make the frames. Once that dried, I painted the actual eye details right onto the lenses. It was hard to do this freehand and get them in the same position on the lenses, the same size, and the same shape.