Big Guy & Rusty the Boy Robot - The Big Guy (voice of Jonathan Cook) is a 12' 10" tall robotic exo-skelton controlled by ex-test-pilot Lt. Dwayne Hunter on the animated cartoon THE BIG GUY & RUSTY THE BOY ROBOT/FOX/1999-2001.

Described as a fancy tank with a soldier inside, the BGY-11, a.k.a. The Big Guy was built by the army to protect Nutronic City. When Dr. Axel Donovan created a 3' 8" tall boy robot named Rusty (voice of Pamela Segall) - the latest advance in true artificial intelligence - The Big Guy was retired.

Unfortunately, Rusty couldn't live up to his billing when a huge purple alien from space began smashing the city. The ultra-patriotic Big Guy was resurrected and attacked the alien. When acid ate though his armored arm, BG said "Some times a soldier has to say a farewell to arms. He then merged his damaged arm with Rusty's nucleo-protonic power and defeated the alien. After BG contained the alien threat, the army re-commissioned Lt. Hunter to partner with Rusty and direct his skills and development.

BG, a "For God and Country" minded robot, can hurl missiles, fly in the air and fire weapons built into his arms [when he cocked his arms, his elbow opened to reveal lasers and machine guns. BG travels around in a huge blimp shaped aircraft.

The red haired, Rusty ["I may be small but I'm a pretty darn good robot"] wants to grow up to be just like Big Guy unawares that BG is actually just a robotic skeleton. 

Career scientist Dr. Erika Slate (Gabrielle Carteris) from Quark Industries designed Rusty's prototype and maintains his systems as well as a motherly friendship with him (Rusty has no pain receptors but can feel hurt due to circuits that make him feel emotions.)    

Big Guy & Rusty the Boy Robot
Theme Song Lyrics

Watch the skies coming at you
a hero of metal hue.
He locks horns with disaster
for the red and white and blue.

Then was born a boy robot
miracle of science.
Ready to battle large monsters
supercharged, and 
pretty darn good but he needs help...

The Big Guy he's a ...
heart of gold and fists of steel.
Clobbering, he (garble) deeds,
with Rusty at his heel.

...they're a mighty team.
The boy robot lives his dream:
to be a legend in history
the Big Guy and Rusty.