"The call of Korriban is strong, but it is the call of the dead." -Darth Sion
This custom is one I've wanted to do ever since KOTOR II came out, and I kept putting it off, and putting it off...but finally, I had all the parts I needed, for the most part, with the right mix of being somewhat true to the source material, and yet with a little more flair and artistic license. I also wanted to make sure this figure had some poseability to him. So first, here's the reference shot:

A twisted wreck, Darth Sion is a Sith Lord held together only by sheer force of will. Every bone in his body has been shattered and rebuilt, turning his skeleton and his flesh into a patchwork mass of bruises and scraping bone. He is in constant pain, and only his hatred and the power of the Dark Side keeps him alive.
And here's my take on him:

And vs. Master Vandar:

And a close-up of the facial detail:

A few things about this custom...the flash is washing out a lot of detail. I took about a million pics of him tonight, and it just can't be helped. So the version you're seeing is missing some of the subtle coloration through his cracked and pitted skin. There's also a few details I still want to add, like the little flap hanging from his waistline in the reference shot, and the buckles along his gloved arm...but I wanted to get a pic up tonight since I promised I'd show what I had been working on.
Also, I apologize for the small size of the pics...for some reason Photobucket keeps resizing the images, and I can't seem to adjust it.
Anyway, here's the recipe:
Head and neck post: ROTS Mace Windu (with Epoxy)
Torso and arms: GI JOE Major Barrage, dremeled and epoxy added)
Left Hand: Evolutions Dooku (Can be swapped with Sith lightning hands as well)
Legs and crotch: Clone Wars Saesee Tinn
It's a shame I can't get a pic that really shows the detail, because as of right now, this is probably my favorite custom that I've ever done. I'll try to get some better ones when I update again this weekend.
-DD