I started the process searching the Internet to see what others have done and also printed out a photo from the movie. The goal was to get as much information, good or bad, so that I could design the 4 mail characters plus toto.
I hope you enjoy this instructable and if you have questions please ask.
Step 1: Establishing the Height
My plan for the 4 characters was to make it all in wood other than hair. Dorthy's dress is all wood cut on the lathe then sanded on the oscillating disc sander to shape the contour. I did the same with scarecrow's hat.
Step 2: Turning All the Pieces
The Lion was next turning a pot belly and a slightly pear shaped head. After turning the body I sanded the back to give the pot belly shape.
Last was Dorothy, as I wanted to make sure her height was the same as the others, flaring the bottom and establishing the waist with a belt line. This again was going to be sanded on the Disc and Spindle sander to get the shape.. See photos..
Step 3: Cutting the Slots for the Cracker Lever Arm
Step 4: Cutting the Arms and Legs
The legs are all dependent on the body and head height. These are all turned with 5/8" dowel to get to 1/2" dia.
Hands are shaped round on the end of the arm.
Step 5: The Base
I started with a flat base approximately 3"x 3". I then cut and sanded 1/8" pine pieces to get the shape
Step 6: Figuring Out the Painting Scheme
It also allowed me to focus on the details before applying a drop of paint.. In woodworking measure twice and measure again..
Step 7: Tin Man
The oil can was turned on my lathe then handle added. The axe is all of wood cut and sanded.
Step 8: Dorthy
For Toto, I started out looking for a dog I could buy then paint.. No luck, so I made one from wood.. Bandsaw, file, chisel, and sandpaper drawing the shape, and refining as I worked it..
Lately ruby red slippers.
Step 9: Scarecrow
I used burlap on the bottom of the head to match the photo of the cast in the movie.
I also added a black crow..and apples from the tree that threw them at him.. They were also turned on the lathe.
Step 10: Cowardly Lion
I drilled out holes for whiskers on the face, and made the badge of courage on the bandsaw.
In the movie I always remember his tail and him grabbing it. So I made the tail with string and put a piece of the hair I used on the end..