Warning: lots of pics ahead
I started with pink insulating foam. I cut the general shape for the base to start and worked my way up. Once I got a good stack I realized it wasn't tall enough so I added one more. They were glued together and shaped with my foam knife (I use a dollar store bread knife because its serrated. One day I will get a foam cutter, but I use foam so rarely it's not worth the cash) I added a rectangular head and I was off. I then started the body panels, using a medium tyhickness cardboard liberated from where I was temping a few weeks ago. I cut them all at once, numbering them as I went so I knew what went where. These were to be hot-glued so I wanted to do them all at once.
All the panels were attached, forming the outer shell of the big guy (see left). I then used some card as seams, filling the gaps between the panels. Every strip was exactly 1 cm thick.
I then used some plastic tubing from the local hobby shop to fashion some Big Shoota barrels and attached them to the front.
Then I wanted to give it a more ramshackle and Orky look so the body was covered in random armor panels. Orks love rivits so I used straight pins to both reinforce the skin and give it the right look. The paint I was using doesn't like metal, so when it chips off there they will really stand out.
The arms started off with a triangular framework, 2 per arm. All the plastic I used was on the thin side to make cutting easier, but almost everything had to be doubled up for strength.
The forearm was a simple strip, which I then reinforced with more tubing to give the appearance of hydraulics. The klaw was two pieces, put together in a similar style as the Nob Klaws on the GW kits. They were attached by cutting a slot and putting it in with more hot glue.
The flamebelcha I wanted to look like several linked flamer nozzles. I started with more tubing and added a piece of wire, bent to look like the igniter (it helps to have a wife that makes jewelry...I have wire everywhere)
They were attached to the beast's chest and angled for optimal spray.
The twin-linked Big Shoota was cut from an AOBR Warboss that's being converted into mad Dok Grotsnik.