My biggest Mego custom project to date is Dr Octopus. I ordered two different Doc Ock dolls from the 90s to make him happen: a 9″ Spider-Man Origins doll for the head, and a Toybiz Special Edition Series 12″ doll for the bitchin’ tentacles. I’ve seen a couple custom Doc Ocks and their tentacles are always on the short side. I wanted mine to be able to stand on his!
I believe this was the project I originally bought my dremel for, which has proven invaluable ever since. I used an extra fat body to practice drilling holes in the torso–juuust big enough for the tentacles to fit snugly without otherwise needing to be attached. The practice run paid off and I nailed it on the first try once I started on the real thing.
Now I can remove them for maintenance as needed.
The costume was made by pal O. T. Puente, and the box was made by Greg Jensen as always. It had to be an extra wide box to fit his tentacles!
On the DC side of the spectrum, I lucked out at the Tucson Toy Show and happened across a custom I had wanted and missed on ebay some time ago: Doctor Fate, with a head sculpt that doesn’t look like a squash!
The Justice Society veteran was a fixer-upper when I found him. He needed new arms, as one hand had broken off, and his face was in need of a good scrubbing. Once that was all done, I made a custom amulet and pasted it onto his chest. Voila!
I remember having the Super Powers Doctor Fate as a kid and thinking he was the coolest looking dude of them all, so this guy was kind of essential to the collection.