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Creating the Sontarans - Radio Times, April 2008

Sontaran General Staal in Doctor Who Image © BBC
Radio Times's Nick Griffiths goes backstage on Doctor Who to find out how old enemies the Sontarans were re-created.

The Sontarans have challenged the Doctor four times before, first in the 1970s, in Jon Pertwee's The Time Warrior, and finally in the 1980s. They persisted because they were memorable: cool, powerful, crazed, even with a head that resembled an over-baked potato.

"We loved the way they looked," agrees Neill Gorton, special make-up and effects supervisor at Millennium FX. "It was very much about going back to the 1970s, to recapture that look and feel in the faces, then go a bit crazy with the bodies."

The former rigid mask is now made of flexible foam rubber to allow freedom of expression, and the armour, though it looks unyielding, is made of a firmer foam rubber, with medieval echoes in its design. And all 12 Sontarans are the same size.

"They're a clone race and come from a planet with high gravity, so they're short and stocky. Russell T Davies was keen they should all be five feet tall," says Gorton. "The hard part was the casting. We went all over the country to find people who could fit inside the costumes."

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