I made a large sentinel head, its really just the face, to carry around with my X-men themed group at this years SDCC. I did not take very many build pics but there are a few I think that are worth sharing.
Unfortunely I do not have a pic of the underlying structure. This part of the build was where I struggled the most. The original plan was to use foam to carve/glue/paint. I had 0 luck with that because the foam I had I could not glue together, I was using white packing foam in large blocks. So after some brainstorming I came up with a new idea. Take a plastic trash can, cut it to the width needed, cut it in half hamburger style (across the horizontal axis), then use some nuts and bolts to secure the two pieces together. The natural curve of the can acted as the curve of the face and part of the bottom of the can was used as lower support. Once bolted together it was kinda flimsy so I bolted in two horizontal pieces of PVC pip to add some rigidity, they also acted as two perfect carrying handles.
I started with a design drawn on a full size piece of cardboard.
I based it off a toy sentinel 
I used a free photo manipulator tool on my phone to erase the parts that would be battle damaged.
Next, I used paper templates to cut out pieces of EVA foam to hot glue to the outside of the trashcan thing.
The gold pieces have no relevance. Painting EVA can be a real PITA (pain in the ass), so my friend suggested we use some thermal form plastic sheets. We went down to San Diego Plastic supply company in Chula Vista and picked up some way too big sheets for about $50. We ended up using about an eight of what we bought. I cut out pieces of the plastic to heat with a heat gun and bend and mold until they fit. 
Here is pic of some of the pieces shaped and glued on.
After all the plastic was glued on the fun and easy stuff was next. BATTLE DAMAGE! We used a mini blow torch and wide drill bit to create gun shots (that cable made) , and a dremel to cut in the slash marks (that wolverine made).
I heated up two sections on the front, my friend put a glove on, then pressed his fist into the hot plastic to create punch marks (colossus). Battle damage is fun because you cant mess up, no stress.
Unfortunely I do not have a pic of the underlying structure. This part of the build was where I struggled the most. The original plan was to use foam to carve/glue/paint. I had 0 luck with that because the foam I had I could not glue together, I was using white packing foam in large blocks. So after some brainstorming I came up with a new idea. Take a plastic trash can, cut it to the width needed, cut it in half hamburger style (across the horizontal axis), then use some nuts and bolts to secure the two pieces together. The natural curve of the can acted as the curve of the face and part of the bottom of the can was used as lower support. Once bolted together it was kinda flimsy so I bolted in two horizontal pieces of PVC pip to add some rigidity, they also acted as two perfect carrying handles.
I started with a design drawn on a full size piece of cardboard.
I based it off a toy sentinel I used a free photo manipulator tool on my phone to erase the parts that would be battle damaged.Next, I used paper templates to cut out pieces of EVA foam to hot glue to the outside of the trashcan thing.
The gold pieces have no relevance. Painting EVA can be a real PITA (pain in the ass), so my friend suggested we use some thermal form plastic sheets. We went down to San Diego Plastic supply company in Chula Vista and picked up some way too big sheets for about $50. We ended up using about an eight of what we bought. I cut out pieces of the plastic to heat with a heat gun and bend and mold until they fit. Here is pic of some of the pieces shaped and glued on. After all the plastic was glued on the fun and easy stuff was next. BATTLE DAMAGE! We used a mini blow torch and wide drill bit to create gun shots (that cable made) , and a dremel to cut in the slash marks (that wolverine made).
I heated up two sections on the front, my friend put a glove on, then pressed his fist into the hot plastic to create punch marks (colossus). Battle damage is fun because you cant mess up, no stress.
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