Thank you so much everyone 
Someone asked about cutting the pieces. All I can say is - sheet styrene, scalpel, a hundred or so blades as the tips break every 5 minutes or less 
Everything you see in there is hand cut, with the exception of the few little found model kit pieces and of course the tiny little torx head screws (which came from hard drives too).
The forehead "spoon" was the most difficult. They're not round holes. And there is depth to that piece on the original. There is no human way to make this piece with that kind of depth by hand unless you get creative. The original appears to be upwards of 1/4 inch thick. So to do this by hand, I designed one side, in one layer, and then reproduced that single half layer 10 times. With those 10 layers, half of them flipped to produce the other side. When all layers were applied, you have a piece that looks nearly laser cut because the depth of each hole is true all the way through, and of course symmetrical hole positions on the opposite side. I have yet to add the little greeblie to cover up the seam. I suspect that Don's was done in "halves" because of the placement of the greeblies down the middle. I'm sure he can confirm or deny, but it's just a hunch
The first rule of thumb on this project was to design pieces in a particular order. If you don't make the right piece first, everything else is "off". So I had to really think about a systematic approach. The mouth cage had to be first obviously. But not work up from there. The forehead had to be next, then filling in the middle to match everything up.
The hard drive reader you see in the pics is "sterilized" for casting purposes. From the side, you can see two of it's 3 arms, the recess between them is filled but an undercut was left to simulate separate arms. The third arm was omitted because you really just can't see it anyway. The idea was a cheaper alternative to hunting down a WD 1020ba hard drive (Which I discovered BTW). But I plan to use an original for my own of course. You might as well use it if you got it 
hbaby
FP
