Hey boys!
I know it has been a while since I posted an in-progress thread . . .

with this post I hope to change that!
So I recently have been reading all 5 volumes of FLIGHT (awesome visual storytelling - great books for anyone to own) and I came across this little bot in a story by Sonny Liew. I liked the simplicity of the bot and so I am using this design as a springboard and inspiration for this build:

I started with the head and decided to hand shape it:

I roughly cut out the circles of styrene (Pain in the neck

) Then welded them together with ProWeld by Ambroid which basically melts the plastic to itself without leaving a glue residue. Then I started drawing them along sanding blocks that I made up of various grits of sandpaper glued to blocks of Corian.
Next I heat formed a sheet of styrene around an empty film container over a flame. This at least started to train the styrene into the desired shape. I ended up welding this 'skin' around a styrene spine I made to the right size:

This is where I was after that stage:

As you can tell from the photos I don't like wet sanding styrene - but because of the dust that dry sanding produces I opt to wear a heavy duty dust mask with replaceable filters. Styrene dust can be nasty stuff to breath into your lungs especially as fine a dust particle that is produced from sanding with a 400 - 600 grit sandpaper. So what do I do with all the left over dust? I save it of course!

Mixed with the ProWeld the styrene dust makes an excellent putty/filler for seams (Mix it as you need it - don't premix it, or you will be left with a chunk of hardened plastic!)
Next I started working on a chest dial that I wanted to mount on a raised plate. So I again laminated 2 circles of styrene together for the base shape - but I wanted the plate to have a tight fit around the curved chest. So, I simply wrapped a piece of sandpaper around the chest, taped it in place and ran my piece back and forth over the sandpaper:

You can see from the second picture that this method produced a nice concave back to the piece which fit perfectly on the curve of the chest.
Next I tried out some 1.0 balls from mechaskunk as rivet heads around the dial. If you haven't visited Fulcy's store yet, DO IT!

click on the Mechaskunk link to the right of this post - you won't be disappointed! As you can see from the picture below, the best way I have found to control these small parts is with a simple magnet. At least this way these suckers aren't rolling around and falling off the workbench!

You can also see how nice a fit the chest piece made:

So that is where I am so far:

All in all this is shaping up to be a sweet build and I am excited to 'be back in the swing of things'!