Before you get started, I would suggest first reading through the entire tutorial. I built this robot using the resources that were readily available to me, but you may have different tools and equipment at your disposal. I used a jig saw for fabricating the majority of the parts; however, a cnc router would offer far better results. The eye lids were also hand made using Shapelock, a drimel, and a toy ball (from a Robosapien V2); again, better equipment such as a 3D printer would have offered better results.
The parts which are cut from the sheets of expanded PVC were first designed using Adobe Illustrator. I have provided the original files for both reference and editing. Those files were then printed to scale using a wide format b/w printer at Kinkos. Using tons of removable double-sided tape, I outlined the parts on the reverse side of each printed sheet of paper. The sheets of paper were then placed carefully on the sheets of expanded PVC.
Parts 1 PDF: White Expanded PVC 24" x 48" .240" Thick
Parts 2 PDF: White Expanded PVC 24" x 48" .120" Thick
Parts 3 PDF: Gray Expanded PVC 24" x 48" .120" Thick