To start leap forward from 1985, I'm assembling a CAD model. I'll sacrifice a couple minute features, but I'll do my best to nail the overall dimensions. As I start the CAD, I've already noticed a few odd features:

• Nintendo hails from Japan, but many of the dimensions (3.00[in], 0.3125[in], etc.) are imperial. (Could the R.O.B. model designer be American?)
• Outside, R.O.B. looks clean and polished, but on the inside of the shell, I can see some interesting grooves and patterns on the ABS. I suspect that the original R.O.B. model, from which all copies were formed, was carved from either wood or clay since these patterns seem to have taken on the impression of a block of wood or sculpted clay. Judging by the outer shell, R.O.B. may have first been vacuum-formed from a solid template block (wood or clay?), after which a mold could have been made from these vacuum-formed pieces. I don't have the manufacturing skills to be certain, though.