BoB's body had to be completely redesigned for his new heavier servos.

I choose to keep closer to the classic BoB shape. I hope this will put less stress on the servos, especially on the ankles.

I also modified the design so the front and back panels can be easily removed and changed. Note the "box" towards the bottom of the body.

This means the front and back can be removed, which allows you to work on the components mounted to them without the body falling apart. It also provides cable management of the servo cables.

I completely redesigned the legs in 6 mm ply to give them some more strength. I also originally designed the legs to have two side panels, as you can see from the tab cut outs. However that limited the range of motion for the "ankle" so I left one side off.

The heavy duty servo horns from Servocity worked well. They gave the legs much more rigidity and strength, so no more swaying in light breezes!

I am pretty happy with this as a starting point, now off to do the electronics!

More pictures of the current state of BoB: