I've sent a cuddly robot out into the world. He hasn't gotten to his destination yet, but he was actually really fun to make. I mostly used old t-shirt material.
His body with the love buttons
The head and body piece were 6 equal squares, which I sewed on the extras before attaching. These definitely needed pins to hold it together while I sewed.
A rough idea of the body
I attached his arms and legs with coordinating buttons
And finally, the box I sent it in...
I attached his head to his body with a hidden stitch using embroidery thread. Probably not the greatest sewing job, but it won't be seen. I must re-iterate that the new poly-fil I bought makes all the difference in how cuddly things become. Now I'm using Silky Soft Ultra Plush. Before it was just the regular stuff. The silky soft is just amazing!