You don't actually NEED a Dremel (or any other name brand rotary tool). What you certainly could use are the BITS they sell for the thing. They can be found loose or as part of sets from stores like Sears, Walmart, Home Depot and such.

For the sort of project you mention (hollowing a head for a ball joint), I normally drill a hole with a regular drill bit that is as close (but not quite) as thick as the ball of the neck. Then I insert one of those ball shaped dremel bits (one that most closely matches the size of the neck ball), all the way in and then turn it manually.

This will give you better control of what you are doing and reduce the risk of ruining/melting/losing the figure's head.

You will be needing a collet to hold the dremel bits, but most hobby shops will have a suitable pin vise if you ask around.

Uh, it would help to know exactly what do you mean by a Sith body. Do you want an armored body?, A body draped in loose robes?, A combination of both?.

There are some other action figure lines compatible with Hasbro's SW  (think of G.I. Joe, the Chap Mei stuff) that might be useful  in customizing a Sith.

It varies depending on the type you bought. Some are good to sand and paint in under an hour, some reach workable hardness after 12 hrs.

Normally the blue/yellow stuff cures completely in about 10-12 hrs, while the blue/white cures in a couple hours. There's also  the red/green variety, which cures faster, in under an hour, but I find it a lot more coarse.

Kneaditite is one of the names for the two-component epoxy putties out there. Usually the putty you find at regular hardware stores is older and drier than the one you find at hobby shops, but their formulation is pretty much the same.

Depending on formulation, the curing time varies from 5 minutes to a couple hours, with the maximum hardness reached after 24 hrs.

I normally use the quick setting epoxy to  shape the basic outline of whatever I'm working, and then use the longer curing one to  add in details. I've known modellers that work the exact opposite way, using the quick setting epoxy for detailing, since this way they say there is less risk of destroying by accident what they had already done.

Most impressive!.

She totally looks like something Hasbro could have offered along the McQuarrie Stormtrooper.

Those are most impressive!

What hue of red did you use for the shocktroopers?
All of them are good, but I specially  like your Enchanted Blue clones.

I used the #41 Clone and decorated him using Citadel acryllics.

I finally have ONE. Got it off of eBay, and I find it perfect. Now I want more...