Operation Recall Breakdown Of Preproduction Process

Carson of 3DJoes has shared a new update, where he takes us behind the scenes to check out the inner workings of toy production. Things kick off with a breakdown of the preproduction process. Check it out below –

THE PREPRODUCTION PROCESS

If you’ve ever wondered how vintage Joes were made, this is the update for YOU! 

I. DESIGN WORK

First up, Ron Rudat or Mark Pennington do a TON of design work, including ideation, revised line art, color studies, final color study, and presentation art. Then Doug Hart creates the package painting. That’s all of the 2D work. Here’s a look at that process: 

II. SCULPTURE

Figure sculpts were made using the artists’ medium of choice. Some used 2-part epoxy, while others used wax or clay. Hasbro created many different toy lines and their internal staff could not sculpt everything. So while some sculpts were created in-house, most of the G.I.Joe: A Real American Hero sculpts were created by external contract artists. See the Bill Merklein Creator Profile to view the work of one of Hasbro’s most prolific contract sculptors.

​Below you see the 2-Up sculpt for Dar Reapers. The buck was printed in gray resin and the multicolor white, gray, and tan material was added by Bill Merklien. The head was sculpted by Mike Good.  

Bill Merklein was perhaps the most prolific figure sculptor behind the G.I.JOE: A Real American Hero brand. He worked for Hasbro as a freelance sculptor from 1983 to 1989 and during that time he sculpted over 70 G.I.Joe figures.  Mr. Merklein’s career went beyond the G.I.JOE brand.  He also sculpted toys and statues for Air Raiders, Alien 3, COPS, Dungeons & Dragons, Mighty Max, Star Wars, The Crow, Visionaries, X-Men and more. Bill’s passions go beyond toys, he is a prolific painter and military miniature sculptor. Check out his creator profile on 3DJOES to learn about his impressive career.

Bill brought Mike Good into the fold in 1987. They were good friends with a great passion for sculpting military miniatures. Mike came on as a freelancer as well and sculpted dozens of G.I.JOE: A Real American Hero figures over the next few years. 

Dark Reapers’ hand sculpted 2up is available for auction here!

III. PAINTMASTER

2-Up resin hard copies were hand painted and used as a final color reference. At least two of these “paintmasters” would be made. One would be sent overseas to the factory, for reference as they created the final paint masks. One would be kept at Hasbro for reference and cataloging. We did the same, as we’re following the vintage process! 

This is a one of a kind resin cast that was hand-crafted by our friends at LIGHTBEAM3D. It was then painted by Chris Scott (of World War Hell fame!) and taken around to conventions to show the development of the Operation: Recall line. It was also photographed and used to create mock up MOC (mint on card) packaged product photos for the web site and the trading cards. 

This 2up is nearly 8″ tall! 2ups are named for their 2:1 size ratio when compared to the size of the planned finished product. Hasbro used a 2:1 ratio from 1982-1994 for sculpting to allow the sculptor to create a higher level of detail than could be attained at the 1:1 size of the finished product, and so that’s how we’ve been sculpting Operation: Recall as well! 

The Dark Reapers 2up paintmaster is available at auction now!

IV. 3D Modeling Revisions

Every hand sculpted 2up was cast in resin and sent to the factory for scanning, along with the only other existing paintmaster! These scans were then revised digitally by Carter!, another veteran Hasbro sculptor that has brought incalculable commitment and detail to these figures. 

V. 1:1 Factory Model

Now that Carter! and the factory have hammered out the 3D files, it’s time to make our first 1:1 version of each figure. This one of a kind  1:1 factory model resin of Operation: Recall’s Dark Reapers was hand-crafted by our friends at the factory in China before making it’s way to 3DJOES HQ. This resin 1:1 figure is fully articulate and was created as the final step before we moved on to cutting metal tooling and pouring plastic. The factory 1:1 model is available at auction now!

VI. Test Shots!

Once the final model is approved, things get EXPENSIVE! This is when you cut metal tools, and let me tell you, this is the primary expense in toy manufacturing. Test shots are factory sample parts pulled from the cut metal tooling. They are created to examine the quality of the fit, form, function, and durability of a plastic part prior to mass production.

Dark Reapers’ test shots are live at auction now!

These were hand-assembled by our friends at the factory in China before making it’s way to 3DJOES HQ. 

NOTE: cardback and insert have embossed Orthrus split skull security seals! 

VII. EPs

Engineering Pilots and Final Engineering Pilots are samples of near-production quality toys supplied by the factory for approval before mass production. These samples were used in review to verify paint detail placement and articulation. Examples of FEPs have been found with different paint applications or plastic color compared to what was released for mass production, as changes can still occur. 

The Dark Reapers EPs with proof cards, FEPs, and Carded FEPs are all available at auction now!

Everything I’ve just written is a gross oversimplification of the ARAH ​preproduction process! ​For a much more comprehensive breakdown of the ARAH preproduction process in 26 steps, please check out this page on 3DJOES for more detail and imagery than I could ever fit in a Kickstarter update. 

Thank you as always to Chris “Topson” Murray and Pat “Notpicard” Stewart of Joe Declassified for sharing their expertise with the community! 

You can own a piece of toy history!

Over the next several weeks I will be auctioning off one of a kind Operation: Recall preproduction artifacts. Visit the 3DJOES eBay page to see them all, and be sure to save the seller page to see future offerings!

There’s one complete set of Wave One revised test shots and cardback / insert proofs that I just couldn’t bring myself to split up – so those are all together. Who’s that fifth figure?!  Yes sir, a Were-Jackal test shot is included! Please check that auction out here.

All prototype sales go toward funding the development of year two figures. 

Thank you ALL for supporting Operation: Recall, and helping these legendary creators do what they do best, create timeless action figures!

– Carson

P.S. Wave Two is IN PRODUCTION at the factory. If you missed the last update, we shared tons of awesome Wave Two photos! 

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Many thanks to Carson for sharing this piece with the community!