Step 1: Parts:
2 Rechargeable 1.5v batteries
Copper plumbing parts
Brass & copper wire
Copper mesh or beer can
Step 2: Battery:
Step 3: Circuit:
I really like the simplicity of this circuit and wish I had done a better job showing it off.
Step 4: Robot Shell:
Drill holes in the end cap for the eyes and in the body for arms, belly button, satellite pole and wires. I use a hand drill and go slow, starting with a small bit and stepping up bit size incrementally.
I made the mouth with a Dremel and a cutoff wheel, but a hacksaw would work fine.
If you're feeling fancy and/or have them on hand finish the holes with aluminum grommets. On some I just used rivets for eyes on others it's a grommet + rivet mix.
Step 5: Soldering Arms:
I went with a four finger hand approach because it was easier to use small V's of wire.
I like to pretty much get the arms and fingers into position at this point because If you didn't do a very good job soldering they will break off. It's easier to fix now without the electronics inside.