FINALLY!
He took about 2 weeks, 2 1/2 bags of polyfill...but he was worth it!
His body is made of silver costume fabric, and the bottom is pilled fleece for stability. I made his face out of the same costume fabric, along with some fancy red silk stuff and a red button for his face and a piece of suede for his nose. His neck is made of black glacier fleece, and stuffed like crazy to hold him up (he still needs a bit of help, if I make another one his neck will be smaller and wider so his head doesn't flop around), and his collar is simple quilting fabric. I made his screen of the same stuff as eyes, but in silver, along with some suede. The button panel at the top is felt and suede, and is in the correct order (according to the show). His K-9 is hand drawn on white glacier fleece and glued on with fabric glue.

He measures:
29" Long
11" Wide
17" Tall