Bah, I've not been on the RPF for ages as I'd forgotten my log in.. if I'd have remembered them a bit earlier I may have been able to help you out- I've just helped out an exhibition with Matt and he had the original prop there.
I don't know how recent you are aiming for with the look of your replica, but here's Matt pointing out the new rivets on K-9's head, he's got so fed up of the screws being obvious he decided to make it a design feature!
In addition we had two other K-9's on display, so we took a group shot after the event had finished and we were packing up! The original prop is in the middle!
GeneralFROSTY - thanks man, that means a lot. I have been putting my heart and soul into him. He is being dedicated to a buddy of mine that is perhaps one of the best Doctor Who/David Tennant costumers/look alikes who is in the hospital fighting for his life.
Stuffj/Aaron - he is made out of mostly 3mil (1/8") styrene with some 1 & 2 mil styrene mixed in.
"Skinned" simply means after you have built a frame work, then you put a clean layer of thinner plastic or material over that frame to give it a "skin". Look at the photos at the beginning of this thread - you'll see the frame of the robots head, it now has a layer of skin on the outside to cover it all up. Make sense?