One of the coolest jobs I've worked on in the business was this full size Megatron. From belt buckle to the floor he measures 25' tall.
A foam "sock" representing the interior mass was fitted to a steel armature in 3 separate sections. The sculpted bead foam individual robot parts were attached to the sock and the 3 sections were then stacked (pictured).

The foam was hard-coated, sanded and given a base coat of paint.

Here is Megatron on his stage with various techniques used to make him look frozen and ready for camera.

The ice cave where Megatron was found in the artic.

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