Very impressive find - but these are only images Sideshow released, right? Not the actual 3D files?
While hypothetically doable once you have the 1:4 scale Grievous model in hand, I'd like to inject some real-world numbers here.
3D Scanning of all the parts - including part orientation & fixation, scanning, cleaning up the files (filling gaps, fixing wonky surface errors, etc.), exporting in .STL format for rapid prototyping: at least $10,000
Rapid prototyping - includes .STL file import, orienting the part on the build plate, setting the resolution parameters, and machine time: at least $50,000
These numbers aren't sucked out of my a$$. I do this for a living. A stereolithography part typically runs (conservatively) about $300 per 4 square inches, and the larger, more complex shape, and difficult the clean-up, the more expensive.
Material & labor to mold all the parts - at least $5,000 (good for maybe 50-60 pulls before requiring replacement)
Labor, material, and hardware for casting, cleaning, painting, and assembling all the parts - at least $5,000 (or $2,500 for a kit)
So just preproduction costs alone would come to $65,000, conservatively. And let's say as many as 20 people committed just to kits - to just break even on the investment, a kit would have to cost $2,500 + $3,250 = $5,750.
I'm sorry to be the voice of skepticism, but only a licensee with a sound corporate structure, efficient bookkeeping practices, and sufficient operational capital could pull this of, but that's only hypothetical, because this character is not popular enough to merit a license or 1:1 scale statues.
If anyone disputes my numbers, they'd better be able to back it up. Don't be naive: manufacturing a product of even modest proportions with only a few parts involves several thousands of dollars, and that's before the first finished product even leaves the factory.
If someone here has deep enough pockets and is willing to risk a Lucasfilm lawsuit, more power to you.
I'll continue to watch as the token skeptic.
- Gabe