I started with a Longshot, added a Cage head, gloves and the skirt. I sculpted the vest and shirt cuffs. To make the horns I dremmled holes in the head and cut toothpics to size and used sculpy to hold them in place. The Lightsaber seprates and is made from an old TMNT sword
toothpic idea rocks socks
When I made my darth maul
I just added sculpt and dremeled away sloppy so it had a sharp bone feel