For those who don't play video games, you may not know ClapTrap from the video game Borderlands. I couldn't stop after R2, so I jumped right into another side project between jobs:
The build diary is available at www.haffnersigns.blogspot.com but I'll post some of the pics here:
Here's what he looks like:
Here is the 3D model:
Here is the model all sliced up and carved into some foam: