Need help with special customization of figures

Posted in Custom Workstation

Here is my project, I am converting a set TMNT action figures 22 in all into foosball players. One side TMNT, the other side villains. I don't know how to do certain things, this is how I plan on executing some of it.

First need to drill 5/8" hole through side of body just under arm, best way I found to do this is to step up the drill bits and work my way, very very slowly to 5/8". The problem im having is the arms. They are not ball type so I can't just pop them out, if I crack open the body to remove them then its almost impossible to drill the 5/8" hole without damaging the body and having to start from scratch cause its to cracked or damaged or warped from trying to keep it held together while drilling. Is there a good putty or epoxy I could fill the entire body cavity with to make it more solid and keep the two pieces together so I can drill it once hardened? I also need to fill in the area at the crotch where the legs connect cause in order for them to kick a ball they have to be a stiff solid piece and can't move, what could I use for this? Im relatively new to this whole thing so please help. Im familiar with jb weld from machine repairs and household repairs but it comes in such small amounts I would have to buy dozens of packages in order to do all 22 players, action figures. The arms and legs and head I plan to use simple holes drilled in both the main body and body part and gluing with use of a pin inserted in each end to reattach and keep them from moving so im not worried there, and I know how im going to make the legs straight so that they are more like an actual foosball player. My big problem is what to use to fill body cavity and the sockets for the legs to make sure they can't move and hopefully won't break.