This isn't my typical custom figure style, but a Mom contacted me via Etsy, requesting this specific custom figure for her son's upcoming birthday. I thought it was great to help a parent who supports their kids imaginative playtime so much.
The mother had tried cutting off the arms of other figures and attaching them for her son, but they wouldn't hold.
She sent a Galactic Heroes Hoth Han Solo + an Young Obi Won for the lightstaber.
I cut the bottom and top (at the shoulder) off of the Obi Won figure - creating a "C" shape that had the arms on either side. I cut the inverse of this out of the Han Solo figure, superglued and clamped the two together. I added some Epoxy Gel afterward to further strength the bond. After that cured, I resculpted the blend area with Aves Black Apoxie sculpt, sanded it down, and gave it a few coats of Tamiya paints.
Afterward, I sealed the face, chest and shoulders/arms with superglue. I left the lightsaber alone, as I figured it would receive the most play wear, and it was made from a soft plastic - not idea for coating in Superglue.
The figure was sealed with Vallejo Matte Varnish, then packed up for his new owners birthday.