Wood

Chicken wire

Foam mannequin head

Coat hangars

Sand

Foam chips

Electrical tape

Maul costume, mask and lightsaber

Sculpey
 
 

My husband made a wooden "skeleton" about my height (Maul was short) and I covered it with chicken wire to "flesh" him out a bit. Holes were drilled into the ends of the arms (which are movable, by the way), where I inserted and hot glued coat hanger wires for fingers. I was then able to bend the fingers to hold his lightsaber. Before putting on his gloves, they were filled with a combination of foam chips and sand. The boots were padded with foam as well. The head was made from a foam head, covered with a Lucasfilm rubber mask. I filled the mask holes at the eyes, nose, mouth and ears with   black electrical tape. I then placed the mask on the foam head, filled it in with padding so it wouldn't sag, and taped it in place with black electrical tape. The head is secured to the skeleton on a pointed pole. I then repainted the mask to make it more accurate with more details, especially in the eyes. 

The hardest part was dressing him! I was able to use the costume I made (see story linked above) and added our two-sided lightsaber. Now he stands guard over our collection  saber in hand. I must admit that I get a little "freaked" when passing by him!