I have noticed a strange inequity between the poseability of girls and boys dolls. Most of the female dolls have stiff arms and legs which permit them to do little more than model clothing. To rectify this, I will attempt to turn a very cheap Dollar Tree girls toy doll into a fully poseable action figure.
Step 1: Materials
super glue (also $1 at the Dollar store)
hot melt glue ($1)
florist wire ($3)
hot melt glue gun
pliers for bending and cutting wire
very small drill bits (as thick as or smaller than the florist wire)
optional: hot knife for cutting plastic
Step 2: Disclaimers and various warnings
When cutting plastic with a hot knife, make sure a window is open and there is good ventilation. Better yet, do that part outside, the vapors are probably not good for you.
Step 3: Knees, ankles, elbows and wrists
The following sections might be disturbing to little kids, so you might want to do the doll surgery when they are not around...
Using the jeweler's saw (or a hot knife), separate the doll arms and legs into sections at the knee, ankle, elbow and wrist. Try to create the knee and elbow lines symmetrically so they line up evenly in the final assembly.
Using the pin vise, create a starter hole in the center of the leg. Then use the hand drill to slowly drill out a hole about a half inch deep in the center of the lower and upper leg and lower and upper arm.
Do the same for the feet and hands, but make the hole only a quarter inch deep.
Go slowly when drilling the forearm and ankle. The plastic is very thin and it's easy for the drill to get off center and go out the side instead of straight down.
Step 4: Joints
Trim away excess wire, but leave at least 3/4" extending out of the hole.
Connect the upper and lower legs and arms together with the florist wire and super glue.
Step 5: Torso
Remove the head and use the jeweler's saw or hot knife to cut away the ball joint of the head.
Remove the arms by pulling them off. They should come off easily.
Cut the hips away from the torso at the waist.
Cut the legs away from the hips by passing the saw blade through the hinge.
Step 6: Reattach the legs with wire
Drill holes in the upper part of the legs as shown.
Line up the legs with the torso and trim the wire to the appropriate length.
Apply super glue to the ends of the wires extending from the hips and insert into the upper leg holes. Allow to set 15 seconds.
Step 7: Reattach the arms with wire
Preparing the arms for reattaching is the trickiest part. Drill a hole vertically through the top of the upper arm. Then drill a small hole perpendicular to the vertical hole as shown in the first photo.
Work a long length of florist wire into the side of the upper arm as shown. You may have to curve the wire slightly to get it to go in and down into the vertical hole. Once the wire is worked in as far as it will go, remove it, apply glue and reinsert it. This is the hardest part.
Thread the arms into the torso by passing the length of wire through the holes at the armpits.
Set the torso aside.
Step 8: Prepare the head for reattaching
Invert the head and fill it up with hot melt glue.
Insert the two lengths of florist wire into the head as far as it will go.
Set the head aside until the glue sets. Check for drips and remove them when the glue is cool enough to touch.
Step 9: Attach head to torso
Thread the wires extending from the head through the neck into the torso.
Be sure the arms are threaded in fully.
Invert the torso and fill it up with hot melt glue. This will secure the head and arms to the torso.
Step 10: Attach torso to hips
Fill the hip cavity with hot melt glue. Thread the torso wires into the hip cavity. Set aside until the glue sets. Check for and remove drips when the glue is cool enough to touch.
Step 11: Optional: head sculpt
Maybe try and make a head sculpt and see how it turns out.
Using a hot knife, remove the face from the doll head as shown.
Fill the void with sculpey (skin colored sculpey would be best, but I don't have any on hand).
Try sculpting a face, just for fun.
I have no idea how I would cure the sculpey with the hair attached like that. I don't think the hair or the plastic would survive in the oven. Sculpey is probably not the right choice here.