To be honest I think I've taken this design as far as it can go (though I'll probably find something else I want to tweak lol ^^;)

This was more of an experiment in refining my painting skills, particularly with creating realistic metallic surfaces. For her hair I gave it a more wispy appearance as the old version looked more like a solid piece then what I had originally envisioned (a series of hundreds of metallic fibers that made up her 'hair'.

I also added a slight transparency as well as painting in a few individual strands by using lights and shadows to create the desired effect.

For the skin I used at least 3 individual light layers to create the reflections and refractions rather then using the dodge tool (its a bit more time consuming but the result is far better looking IMO)

for the metal I tried to avoid a pure, clean look buy using a subtle custom paint brush to give the metal a slightly worn feel, while still having it look clean and polished.

from a physical design standpoint I slimmed down her 'boots' to get rid of the megaman/reploid leg design to help accentuate her feminine curves.

I made her face slightly rounder and broadened her snout based off reference from Archie's Sonic: mecha madness special (probably the best draw sally in the comics IMO)

Again this was done to create a more feminine and eye pleasing form.

Her eyes are probably the biggest change since I usually used a solid color with a slight glow for her older designs. (to match more closely with how Robian eyes looked in the SATAM cartoon) This time I opted to use a style similar to metal sonic from Sonic CD but instead of a red ring with black I though it would look more appealing to have the center be white with a blue ring, Though by doing it in this style I may have detracted from the whole mechanical, eerie quality that the eyes usually have.

Overall I hope you enjoy it:)

gonna be working on some new designs in the mean time ^_^