Mister Handy – Codsworth Replica

Because this had to be a lightweight build I worked with foamboards mostly and used Cosplayflex to strengthen the surface.
I was concerned on how the weight would be the more parts I added to Codsworth’s body, so I was forced to build as lightweight as possible.

The base for Codsworth’s 3 arms needes to be sturdy and I wanted them to rotate like seen in the game.
Therefor I built the base around a large piece of plastic pipe.

Codsworth’s head is based on a huge styrofoam sphere (40 cm in diameter), cut into the desired base, and covered with EpoxAcoat, a brushable resin which was perfect to seal off the styrofoam. The surface could be sanded with a bit of effort and a coarse sandpaper.

The stand for Codsworth was built with a thick metal pipe screwed into a wooden base, which had 4 wheels so our companion could be moved around on conventions or at home much easier.
I sealed tricky placed with EpoxAcoat to they couldn’t get damaged if someone accidently would push Codsworth.
The head would be placed on top of a foamboard and could be removed anytime to get access to his “brain” which would be the sound board, the eyes, or things like that.

Most parts I built with the foamboard/Cosplayflex method.
I chose from various foam thicknesses (2, 3, or 8 cm) and cut the shapes roughly, then added the details, sanded everything down until I was satisfied, and then covered the whole surface with Cospalyflex.
This technique allowed me to get lightweight, but sturdy parts for this build.

Most parts that could be glued on I used ExpoxAcoat for them. Because it is really tear proof and it hardens out fast.

Screws and bolts were used to hold the joints together. I also put a few pieces of Cosplayflex where the bolts were placed, so these parts wouldn’t wear out. It’s yet to be tested for how long a bolt would last until I have to tighten them.

I don’t have many powertools at home, so I did the best I couldn’t with conventional tools like my plastic ruler and a knife. You may have a bandsaw or similar, so you could easily cut out all the pieces you need.

A few more joints are needed here and one arm’s almost done! The Cosplayflex/foamboard technique works very well so far. Let’s see later when all the joints are attached if the build still promises the same stability.

Here’s another view of Codsworth’s head and the arm base.