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I've been thinking about this for a while. I like Orks, but I don't like them at the same time. I love the vehicles, and their general silliness, but their faces annoy me, so I've thought about kitbashing some Ogryns in there and even using some Ogres from fantasy, and then painting them flesh coloured, rather than green. Has anyone done anything like this and do you have any advice. How could I justify this fluff-wise? I've considered the idea of some Ork spore mixing in with human genes, or maybe even Marine gene-seed if that would make more sense. I would play them using the Ork codex.

I've always thought Orks were an excellent model for Thunder Warriors, the proto-Space Marines Lead by the Emperor Himself. Just paint the Orks pink with bloodshot eyes, in blue-ish gear with lots and lots of lightning bolts. All of their ramshackle vehicles already have a "road warrior" feel, which fits in with the whole Techno-Barbarian culture that ruled Terra pre-Unification.

SJ

I think you're trying too hard to justify it. Ork rules would fit any savage war like race that is more concerned with smashing something than aiming.

Your army can just be some newly discovered alien race, or a human colony that has been seperated from the Imperium.

In case you aren't familiar with it, Google: Digganob.

It's an expansion for GorkaMorka. Basically Diggas are a human cult of wannabe Orcs. I've thought about doing a Digga-army ( orks and/or IG codex ) many times. So silly and awesome.

Just when you think you know all about 40k, something like this pops up! Super cool and interesting idea for an army.

I always thought about it, but just never have had the chops with green stuff to do it justice. Also never found a 3rd party that makes something I'd like. The idea for Ogres from fantasy painted flesh might hold some merit though.

Orks are also some of the best rules currently around for a mutant army.

You could represent the army as a Beastmen Abhuman regiment