Thought I should post something as it's been a while.
I've been a little separated from 'real robots' for a while, as I decided to build a full size Star Wars R2-D2 replica prop. You can check out all the construction pictures over on my website:
My current project is now a C-3PO prop which you can find here:
I built my own vacuum forming equipment for these projects. If you want to ask questions then you can post a comment in my guestbook/forum: