Here are some pictures of Sheldon as he is assembled. As I get time, I’ll try to add more info on how he is constructed, and if anyone wants, I can post the Sketchup or STL files for any 3D printed components.
Early Skins
Initially, I built Sheldon with aluminum “skins”, but I was not happy with the look.
Here are the original aluminum skins
New 3D Printed Skins
I had started making plastic parts for the arm and head, using a Lulzbot Mini 3D printer, and eventually decided to redo the entire skins. I used Sketchup to design the parts, then printed using the Lulzbot Mini, and a Lulzbot Taz 6 that I bought.
Here is a page of Sheldon Mechanical info.
Final skins below. More details to come!