Han Solo with Alternate Head Sculpt from the Skirmish at Carkoon Multipack, SAGA, 2004

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In 2004 Hasbro Toys released a Toys R Us exclusive multipack.  It included a Sail Barge cannon and 4 action figures.  The three skiff guards were re-released figures from the 1999 POTF2 Jabba's Skiff Guards Cinema Scene.  However, the Han Solo was a mix-match of pre-released Han Solo figures with some newly sculpted parts.  The reuse of existing parts has been quite common among the creation of quite a few modern Star Wars action figures.

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1999 POTF2 Han Solo (Cantina)

2000 POTJ Han Solo (Bespin)

2004 SAGA Production Release

 

The production release of this figure included parts from two other previous released versions and some newly sculpted differences.  The head, arms and torso are from the 1999 POTF2 Han Solo (Cantina) figure and the left leg is from the 2000 POTJ Han Solo Bespin Capture figure.  The lower torso and right leg were sculpted specific for this figure release.

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Early test shots of this figure included the head of the 1999 POTF2 Han Solo (Cantina) instead of the 2000 POTJ Han Solo Bespin Capture figure.  It is believed that this head sculpt was strongly considered for the production release, but later changed.  The most notable differences between the two is the neck and head positioning.  The production release has a more pronounced Adam's apple.