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Not affiliated with Lucasfilm Lt. R2-D2 is the conceptual propety of Lucasfilms and used with out authorization.

1.  I used flat 1mm SINTRA for this part. Thin 0.040 thick aluminum or styrene could be used also.There is a LINK to the template I used below. When I cut out my pieces I left the half circle "face" attached to the rest of the piece but the very top of it.1/8 of material was probably all that was holding it together. 2.  Only the 2 edges need to be heated. Start with a shallow angle and bend it as needed after test fitting. The main "arch" will happen when both sides are held in place on the Leg Ankle. 3.  Once you are satisfied with the fit of it. Attach it to the sides of the leg ankle. My legs had wooden walls so I used nails to attach mine. Other methods are possible. Glue, double sided attachment tape, welding, ect. can all be used. Once glued bend the "face" down to meet the "arch". 4.  Once everything is in place you will probably need to Bondo or putty the seams on the sides and the "face". Below is the LINK to the actual template I used for mine.

Click on the black template for the full size template.

Template should be 5.331 inches x 11.151. You may have to adjust it to your legs. This size should fit on legs of "official" sizes. Always make a "mock-up" before commiting to cutting your material.r2-d2

Half-round Ankle Area Construction.