It Took 4 Years to Build This Detailed, Posable Terminator Replica

Metalworking Workshop
It Took 4 Years to Build This Detailed, Posable Terminator Replica

Many years ago I bought a resin kit and built a T800 endo arm. About 1 week after completing it our pet cat became curious and knocked it off a shelf and it shattered. (Yes, the cat is still living!) The project went into storage for a few years to be pulled out later as the beginning of a major build.

YouTube player

Using skills I learnt in a TAFE course (Technical And Further Education), I built my own forge and started building my T800. The project took approximately 4 years and there were many hurdles to overcome because I was building a fully articulated life size Terminator T800. Modified from a resin copy, I had to recreate parts that were static so that joint movement was possible, 230 movable joints and pistons. This included spine, hips, shoulders, knees, ankles, toes and fingers etc.There are over 70 videos documenting the build, he is made from recycled aluminium, weighs more than 130kgs, has over 500 individual pieces, 280+bolts, and 60 hoses and cables.


Apart from casting the pieces I also created the stand which includes artificial fire, electronics, lighting, and a lifter to support the weight as the body was put together. I had a lot of help and support through multiple forums and the world wide web contained a monumental amount of reference materials. As with the first of any project I do there are always improvements I want to make. I love trying to turn fiction into reality. With so many projects on my wish list it is unlikely I will build another T800, which makes this one my prized one of a kind.

My first reaction to anyone wanting to replicate the T800 is to scream don’t do it!! But with all my projects I try to answer all questions and share all my reference material. To make a T800 from aluminium you need strength, tools, and space. As we are renovating our house, he lives in the corner of our lounge room and my wife even had to give up her Xmas tree in 2015, (probably 2016 at this rate!) and settle for a decorated T800.

You can see more of my work on my website.

YouTube player
Discuss this article with the rest of the community on our Discord server!
Jamie Staff

(AKA Jaz) lives in Newcastle, Australia. I'm a 47 year old self-employed mad inventor and while I hold no official qualifications, over the last 20 or so years, I've pretty much taught myself everything that has taken my interest, from magic to metallurgy and everything in between. My dream has always been to get to the stage where I can be making and doing the work I love.

View more articles by Jamie Staff
Maker Faire Bay Area 2023 - Mare Island, CA

Escape to an island of imagination + innovation as Maker Faire Bay Area returns for its 15th iteration!

Buy Tickets today! SAVE 15% and lock-in your preferred date(s).