Just to give you a bit of background info, i collected a lot of broken projectors and other electronic equipment and would salvage parts. However i had lots left over so i made a sculpture from them as a sort of futuristic version of the thinker. a few things to remember if you want to do this, you will need a large amount of parts to complete is and the wire can be very dangerous i recommend gloves and eye protection. also i have a some photos that i couldn't upload so there are some things that i cant show, sorry
Step 1: Materials
30 feet of 3/8 in re-barb
drill with drill bits
thick steel wire
thin copper wire
pliers and cutters
lots of old circuit boards and electrical equipment
Step 2: Design
what I did to make this was measure my general dimensions, leg lent and such, this works good because you can make any pose using yourself to find angles and such. I would recommended you do the same, include parts like rib cage and neck or different dimensions that give you more of a "third dimension".
Step 3: Making the Skeleton
to do this you need to take the measurements from before and mark the re-barb at those lengths, also attach a piece of tape in the middle with the name of the piece or you will not know where they go. next choose a design to shoot for, it is very important to have a design in mind before you start welding. once you have picked it start welding, i found that lying the pieces down at the correct angle worked good, or do small welds at the joints so you can take them apart if necessary. IT IS CRITICAL THAT YOU WEAR PROPER EYE AND BODY PROTECTION YOU CAN GO BLIND OR BE BURNT SEVERELY DO NOT DO THIS IF YOU DO NOT KNOW HOW TO WELD YOU WILL GET HURT!!!!!!!!!!!!!!!!!!!!!!!
Step 4: Giving It More 'body'
I after you have finished welding you should use the thick steel wire to make a general perimeter on the frame so you have something to work off of, make it smaller than your actual thickness as the circuit boards will add depth. Also make sure the wire is tight so it can support the weight of the boards when you do this add alot of wires this gives you the ability to put a variety of different sized boards on
Step 5: The First Peice
This will probably be the hardest part of the project deciding what to put on first, after a long time of trying to decide I found the best way is to simply just put something on and work from there. Start with something easy like a foot or back. I started with a foot, this gave me a good idea of how hard it would be and it was easy to work up from it.
Step 6: How to Attach the Circuit Boards
you need to have holes around the perimeter of the circuit boards you wish to attach, to do this take an 1/8th bit and drill holes, you can go as large or small as you want the important part is you get them on all corners this will ensure a strong hold on the frame/wire. to attach them take either the thick wire, or the thin wire( which works better but not as strong) and wrap it around the the support piece and through the hole you made and pull tight then twist the end shut and cut it off. you can use any thing that is attached firmly for supports just drill holes and thread the wire, as you progress it will become easy. You should wear gloves as the wire can cut you bad like it did me, also it carries the risk of giving you tetnis which is not good.
Step 7: Building
once you get a feel for it just keep going and add pieces however you find best, I will show my progression, keep in mind you don't have to follow any rules and can take it apart and do it again. I had used the rotating disk from hard drives for the major joints.
Step 8: Building 2
as you do this you will find it a lot easier to place pieces as they will sort of jump out at you for a spot, and then it is just like building a puzzle all you need is the right piece, also do not feel afraid to break or bend circuit boards to get a certain shape.
Step 9: The Head
this was rather hard to attach, i decided to use projector lenses as eyes this gave it a sort of mismatched look. then i put a speaker for the mouth, and attached ram and 2 mother board chips to it, and then put a metal piece on top. this gave me the look i wanted, you can do yours however you want.
Step 10: Compleation
I was trying to achieve a sort of "thinker" look however it being made of circuit boards i wanted to go further so i gave it a book to look at, however it is holding it upside down to show it is unable to understand it. also i positioned a fan in one hand as a alternative to having the head rest on the had, I felt that is showed the robot over heating from trying to understand what it was holding.
Step 11: A Few Pics
Step 12: What I Had Left Over
as I mentioned earlier this project was desighned to get rid of my electric waste, this is what i had to start and what i had left, as you can see it is significantly less, i will use the remains in another project.
Step 13: Final Thoughts
This is a very fun project, when you finish i recommend a coat of clear rustoliam, and go through and clip any wire ends short so you don't poke yourself. If you have any questions, thoughts, or want to see more of this let me know in the comment section.