This is an older replica I made of ED-E from Fallout New Vegas. He was made from a 13" guinea pig ball, eva foam, acrylic, and bondo.
Printed some photos I photoshopped to use as templates.
Calculated a lot of arcs
I decided to build him at what seemed to be about 1/3 scale.
Began mapping design onto ball surface.
Began with cardstock templates
Used EVA foam as well
Began filling in gaps with Bondo
Began license plate out of plastic.
Painted and weathered. If I remade at the the present time I would use my Silhouette Cameo to create a better template.
More details and bondo
Got some help with sanding from some friends.
Fashioned the laser from pvc fittings
sanded and primered. Then added some last details.
More details. The antennae are clear acrylic square rods that I later replaces with thinner lighter plastic.
Black Primer. Added the coil. It was bent from scratch from a metal wire.
Added material colors.
Added details.
Put ED-E on a clear acrylic rod. He was very heavy at this point. The bulbs were made from small plastic bottles. I cut the caps off.