As a kid I only had two Battlestar Galactica figures. The Cylon and the Dagget. Of course like most kids, the tail broke off fairly quickly. Years later (before I even attempted a custom figure) I sold off the Cylon. Well since its A) "Star Wars adjacent" and B) a robot, I decided I needed a more articulated one. So I looked for the worst and cheapest beater I could find seeing as the torso and head were all that was needed. Picked one up for $5 at a show.
The entire figure was a little out of scale so I needed a beefy donor for the arms and legs. Vader seemed the best bet and already black. Now the trick with figures is the pins and pivots are often different so I like to try and keep both halves of a joint when possible. I opened up the Cylon torso and ground out the glue posts. I then hacked apart the Vader leaving a ground down torso pivot that would fit up inside the Cylon shell. I did the same with the arms, dremeling a grove around the torso pivot that would be locked in place by the Cylon shell.
After gluing on a soft goods skirt, I glued the torso together. The belt, calf armor, and bicep bands are cut styrene glued in place. My biggest gripe is the one leg seems longer than the other. Never understood how something like that gets to the production stage. Maybe someday I'll make a rifle for him.
