hi,
i am thinking about building a full size securitron and wondered if there where any plans or measurememnts i could follow or if anyone has any advice to constructing the securitron that would be great.
Easiest way to do that is to load the Securitron model into http://niftools.sourceforge.net/wiki/NifSkope; export as OBJ, and load it into http://www.tamasoft.co.jp/pepakura-en/ and flatten it out. You would want to use "http://www.amazon.com/48-96-Black-Gator-Board/dp/B004SRWGZS/ref=sr_1_9?ie=UTF8&qid=1315011268&sr=8-9", but "http://www.amazon.com/Pacon-Original-Foam-Graphic-Boards/dp/B002764CWW/ref=sr_1_5?s=office-products&ie=UTF8&qid=1315011309&sr=1-5" or even thick cardboard would work.
If you are planning a Halloween costume; You might want to borrow a Segway scooter to base the costume around.
My recommendation would be to build the body out of gator board or foam-core; carefully taping seams, and know that you can cut half way through the material and bend it on the cut. After you have a section made, Papier-maché over it to get a uniform shell. Do no less than three coats (allowing to dry between coats), consider doing 6 to 8 coats and a good sanding when done. :shrug:
You could use http://www.iasco-tesco.com/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=647&category_id=31&option=com_virtuemart&Itemid=2 as a sealer (but thinned wood glue with a brush will do the job as a final slick coat after sanding).
Large hardware stores like Loews & Home Depot will stock http://www.lowes.com/pd_259814-62059-51510_0__?productId=1239339&Ntt=flex-drain&pl=1¤tURL=%2Fpl__0__s%3FNtt%3Dflex-drain&facetInfo= that could serve as base for the arms.