Progress so far has been a firm lesson in surface modeling (as opposed to modeling with solids) in Solidworks.
I'm currently debating on fabrication techniques for the shell. So far, I'm looking to either 3D print the shell itself with a resin-based printer or 3D print molds from which I can cast a fiberglass replica.
I haven't run any calculations yet to figure out whether or not the 3D printed material will have sufficient strength to take a few bumps from driving it around. If not, I might consider a DIY attempt at electroplating to increase tensile strength since most of the parts are thin-walled.
A fiberglass composite casting would be more-than sufficient to take a brief beating, but I'll lose the convenience of adding internal features to the inside since I'm only casting the outer surface.
Random thoughts aside, here's a quick peek at where he's at so far:
(R.O.B. sold in Japan arrived boxed with a slightly different color scheme)