This model of the Iron Giant is built using foam core, foam balls, wooden dowels and lots of hot glue.  It is approximately 3 feet tall and all every joint articulates.  I tried to stay as true and accurate to the movie as possible.  It took me around 120 hours to complete.  Except for printing out reference images, I used no digital tools to create this, everything was done by hand.

My process images are below.