Thanks!
The heads on the regular sized guys are cast resin. The head on the big guy is sculpted. I actually sculpted two and picked the better of them to put on him. I sculpt the head separate, glue it in place, then sculpt the neck area (usually just a bit of gap filling on the small ones, but this guy needed a wrinkly neck & a bit of re-sculpted shoulder.)
The feet are sculpted on each figure. I don't think there was a good way to cast them for universal use.
I made a mould for two tails, but haven't had a chance to cast more than a couple of them, so I just sculpted these rather bland ones. I really need to dig out the casting stuff and see if it's still good (not likely.) None of it has been used since before we moved, a year ago.
As far as the club, I tried the trick with hot & cold water. It worked for a day or two, but slowly the club bent back to the awkward angle. It seems that the Bones material has more "memory" than most resins. I just took Shadespyre's advice (thank you!) and drilled a hole down the center of the club and slid a bit of brass rod down it -- and that seems to have worked much better so far. Pics as soon as I get some more paint on them. They're all in the awkward, sloppy early stages of my painting.