After a lot of trial and error I decided to 3d print the legs. The main skeleton is a piece of 1 by 1 steel tubing so the 3d print is just a detail and not a support material. This way I was able to lower the infill and save material.

The 3d model turned into a print once I sliced it properly. My first prints had issues because the filament I was using was low quality. I ended up using them anyway with some smoothing with an ABS slurry.

After many hours of printing I was able to assemble the pieces into two functional legs.

The steel supports bolt onto the main body. This enables me to disassemble Chopper to the point where I can transport him in the smallest of vehicles. He even fits in my DeLorean.