That's awesome. I've been looking into starting to do custom molds myself. I think I have the design/craft skills to do it so long as I practice to get good at it, but that's the problem... getting good at it. And starting.
I have today off work today, I stayed home not feeling well. So between answering emails from work, I'm scouring the board for things that I am interested in. Sorry, Wheeljack, you start too many good threads, and I'm long-winded.

Are larger things impossible or super expensive to recast? I just bought a MyClone Bumblebee and Ultra Magnus, and was thinking about turning their heads into Alternator heads. The BB may be a tad too cartoony, a friend of mine gave me the Wreck-Gar figure, and I was impressed at how good the head looked, despite being a little cartoony. No worse than Alternator Sideswipe's head, I don't think.
The heads are actually in scale with the Alts, I think. Or close enough to not matter, since their heads vary in size depending on mold/character.
I was thinking of molding both those heads with ball joints and perhaps splitting them so I could screw them together... Not sure how to marry that idea yet to actually doing it. The MyClone heads are 1 piece, vinyl-y (soft, anyways) and have a peg that extends from them.
Magnus would work well, but I don't want to paint a Nemesis Prime or Alternator Prime (hate painting large transforming pieces)... I was thinking how hard would it be to recast the arms and the more-frictiony pieces? I could stand to paint some of the other pieces, like the hood, doors, etc. Probably REALLY difficult, or expensive, or both, huh? I'd hopefully cast them in solid colors to avoid the obvious painting, which could yield issues as well.
Unless someone releases a KO Alt prime in white, which I'd buy in a heartbeat. I don't mind KOs so long as they're good bases for kitbashes and not used to replicate something else entirely.