Step 1: Parts List
b) Scanning LEDs - There are several online kits available with the necessary LEDs, resistors, etc... to make your own scanning LED array. I used the one from Thinkgeek, but I also picked up a smaller version that I may use in teddy bear Mark II.
c) Blaster Gun - Not a big deal, but once I had a bear I was able to pick out a gun that looked about the right size for him. Cylons are often shown with blasters so I didn't want Mark I to feel left out.
d) Audio - To get the signature "By Your Command" catch phrase I picked up a few different versions of your stock greeting card/toy voice recorder gadgets. I had planned to use one type and set the button in his paw, but I ended up decided to use the small white hockey puck version pictured below and actuating it by squeezing his nose (it just seemed cuter that way).
You'll also need fabric glue, a zipper, wire, electrical tape and heat shrink tubing.
Oh, and I also used an on/off push button and a momentary on/off push button to control on/off and the speed of the LEDs (the kit I used has 3 speeds controlled by a momentary on/off button that triggers the speed change)
Step 2: The LED Kit
It's a good kit and it was easy to modify for this project so I'm pretty happy with it.
You do need to feel comfortable soldering though so keep that in mind if you want to use it.
Step 3: Extending the LEDs
Step 4: The Finished Scanner
Note that I'm using the Radio Shack voice recorder module instead of the hockey puck in the video (both are visible though). For a while I thought it would work better than the hockey puck but it proved to be too delicate to be crammed into the bear and the hockey puck recorder worked much better in the actual bear.
Step 5: Operation
I felt for the seam in the back of his head and cut a slit big enough so I could empty all the stuffing out and put the scanner array in (so it was useful to have built it ahead of time so I could see how big the hole would need to be)
Step 6: Glue Scanner in Place.
I also considered removing his snout and gluing in a cylon grill, but I decided that might make him too un-cuddly. I saved some bits of fabric to use for filler material around the eyes and elsewhere as needed because my cuts weren't quite perfect.
Step 7: Glue Zipper in Place.
Once the zipper was glued in place I stuck the hockey puck voice recorder in the snout and made sure all the pieces were working before re-stuffing the head.