Hi all you members of internet land! Today I'm gonna be teaching you how I built my life-sized Wheatley replica from the game Portal 2!
you are going to need:
Sheets of "Fun Foam"
a Styrofoam ball (Ours was about 9 inches in diameter)
thick paper plates
an LED push-button light
a spinning stool-chair-thing
determine the size of your Styrofoam ball. you need to measure the circumference and diameter.
Make sure you have enough "Fun Foam" to fill the dimensions of [Circumference x diameter]
cut the foam out so that it looks like a flattened globe. it should look somewhat like this shape:
hot glue these pieces together so that it forms a sphere-ish shape (don't glue the last two together yet)
carve pieces out of the Styrofoam ball to make holes for the eye and "ears" (the eye hole should be deep enough to hold the LED light without it protruding too much beyond the surface.)
cut out the foam into the different shapes that make up Wheatley's "shell". We used reference pictures from the game as well as some fan made 3D models to determine these shapes.
We researched from multiple sources, but this site proved the most helpful: http://www.turbosquid.com/3d-models/wheatley-video-character-robot-3d-model/602446
We used foam to cover most of the sphere. We also used it for various detailing elements.
Color the LED light with a blue sharpie (sounds dumb, but it works) Our LED light happened to already have a crack in it that oddly resembles the crack that Wheatley has at the end of the game.
Paint everything. we used multiple shades of white, gray and brown for the aging to give him that "metal beat-up" look. we also made a reverse paper cut-out of the Aperture logo and used it as a stencil. make sure to use plenty of reference pictures to make sure what you are painting is accurate and on scale. Once everything dries, screw and hot glue the pieces into the Styrofoam ball. paint over these screws to make them less obvious.