So over the next few weeks I carry out come more work on the wooden legs, by adding details such as the 'Horseshoe ' shape at the upper leg areas that is outside of the hubs. i also begin to pad out the ankle areas with more Plywood and a lot of belt sanding.
I find on Ebay a chap who is selling some R2D2 Parts 1:1 out of resin, he's UK based and these parts are cheap for what your getting ! A chap who calls himself Don- Jar. Anyway - I buy several parts, mainly the coin slots and the front vents.
I also decide to make my own skins for the frame. After reading the Yahoo usergroups mails, the options presented are laser Cut Aluminium Skins or Plastic Styrene Skins. Both of which seem to be made in the states and cost a fortune. So I use the plans of the skins that I get printed off at full size, and bought 4 big card board's from Hobby craft. I chose creme color to assist with the final painting.
Pinning the plans to the board and using a brand new Stanley blade and a metal ruler, I took most of a weekend just cutting the skins out - there are two layers to bot the front and the back, working out where and which holes are to be cut.
An attempt to try and record what I did during my R2D2 Astromech Build.......
Wednesday, 23 February 2011
Dome - eye, lights, paints, and wood primer...........
After the dome has arrived, one of the first things I decide to do is to paint the centre eye gloss black, just to make it look a little better whilst I decide what to do with it.
Then it hits me- I can make a Perspex eye. So with a hacksaw blade and Stanley blade, I remove the existing bump that is the ‘glass area’ of the eye, marking on the eye the up and down positions, as I could see that this fibreglass replica does not have a completely true round eye. Its only a tiny bit out of shape but enough to cause refitting problems. I then use some regular filler to fill the removed fibreglass lens section right up so the removed eye is now solid. I done this because I will be heating the Perspex and placing it over the ‘filled eyepiece’, and without the eyepiece being solid – it will melt or deform.
Then it hits me- I can make a Perspex eye. So with a hacksaw blade and Stanley blade, I remove the existing bump that is the ‘glass area’ of the eye, marking on the eye the up and down positions, as I could see that this fibreglass replica does not have a completely true round eye. Its only a tiny bit out of shape but enough to cause refitting problems. I then use some regular filler to fill the removed fibreglass lens section right up so the removed eye is now solid. I done this because I will be heating the Perspex and placing it over the ‘filled eyepiece’, and without the eyepiece being solid – it will melt or deform.
After two failed attempts of heating Perspex in my oven, and getting it too hot till it bubbles up, I eventually get it right. The Perspex I am using is 3mm Clear. I heat the oven to 200 degrees and put the filled eye on a baking tray, then I place the sheet of Perspex over the filled eye mould, and watch through the window of the over and the Perspex looks like melting cheese, and covers the eye. I then carefully remove the baking tray with the melted Perspex and place a mug or china cup over the eye mould, over the Perspex and hold it down so that I get a true ‘close-up’ mould of the eye at the edges. Once cooled, I trim off the edges of the Perspex so that it will fit inside the squared eye holder on the R2 Dome. This can them be glued into position. A silicone sealant would be a good choice, though I actually used Milliput – a fantastic Plastercine substance that when mixed turns to a solid stone like mix.
Once the eye is installed I gave the inside of the eye a coating of Model Quality Gloss black paint. Two coats were used. The result a glossy, scratch proof, non – chippable Centre eye. Happy with the result there, I also installed a colour changing L.E.D to the P.S.I or commonly known as the Red / Blue Light below R2’s main eye. This was great it changed colour and looked great. But did not last long and by the summer this L.E.D which I had taken from a ‘ Colour changing bath pillow, was broken. Whatever light you install, you will need to place then in a reflective case or canister. This is to get the most light reflected out of where the light, and encased so that excess light does not reflect back into the Dome which can be seen at certain points around the head. I found the reflectors out of torches seem to work well. Get the smooth type As the patterned reflectors actually cause a pattern on the diffuser and looks odd.
The diffuser is the exit point for all the P.S.I lights on the front and back. The back ones being yellow and green typically. It’s not a good idea to have clear lenses for these lights so I used Opaque Plastic, the type you would find as covers for binding documents. An A4 sheet of it will be plenty. Just cut a circle of it and stick it to the inside of the dome, again I would use a translucent silicone sealant to get the best seal. When you construct the lights, I would make the lighting unit outside of the dome. Don’t try and build it inside the dome head, room is too restricted. Build the Lights outside the head and mount them inside when they are ready for installation. Be warned, you may need to remove or replace these later on , being for repairs or upgrades , so don’t make it too permanent. You will also need to decide on how these are going to be powered. At the time, I was building a static model, so I was happy to go with batteries and a 12v Set of Blue L.E.D’s Christmas lights for the front Logics. It did the trick and cost me less that £15.
The front logics, I spent a bit of time trying to get a good effect. I eventually brought some blue L.E.D Christmas lights that were able to display a pattern. I drilled lots of holes into a Perspex square and glued each light in place, randomising the position in the drilled plastic as I went. It was fiddly, cheap and effective. As the lights were glued in random positions, when the lights were turned on, the effect was actually worth the hassle. With my limited knowledge of electronics, I assumed that I would be able to take out the circuit board inside of the plug for the Christmas lights and power it with batteries at a later date. Maybe you can do this – but it did not work for me when I eventually took the components out of the sealed plastic plug.
Back to work on the dome. I used a piece of Plastic boarding – the type you would find on a ‘for sale’ sign on a house, as the support for the neck as the fibreglass was so thin in places. I measured the dome diameter and marked out a circle in the plastic and cut around this. I cut some access holes into the plastic and mounted the plastic circle inside of the Dome neck area for added strength. This would later be replaced with a wooded ring, but this was a cheap and free option for me as I had the old house ‘for sale ‘ sign’ kicking around in the garage. Once this was glues with sealant inside the dome neck, the dome itself became much more easy to handle and the strength was evident. In the dead centre of the circle I drilled a hole and mounted a bolt, and on the wooden frame I installed a cross beam made of wood into the neck area, once again with a hole drilled centrally. So I could now place the dome on the body and turn it. It was a very cheap was of doing things, but again it worked. There was a bit of friction, but I installed another nut to the bolt on the dome and a metal washer on the neck ( attached to the body ) and this really eased things. Remember at this time I was working alone with no contact with anyone else building, doing the best I could with little resources and finances. One of the beauties about Droid building is that you can go back an revisit things that you feel need upgrading, changing or repairing later on. Aside form the wooden frame, pretty much everything I had done to date would be ‘reworked’ and improved at a later date.
Now I used wet and dry sandpaper to rub down the dome. Take your time with this as your paint finish will always be a reflection of the preparation of the surface. I then used a Plastic Grey Primer from Halfords Auto Store. Typically it’s the primer spray used for Bumper repairs.
It must be plastic Prep thou, as other paints won’t stick, or if they do they will flake off at a later time. Also the expansion of plastic in the extreme hot and cold will otherwise make your paint crack and fall off. I managed the head in one large can. After this dried, I used a Aluminium colour silver spray paint of the automotive type again. This took 2 cans, but applied in thin layers over a few hours and left to dry at least 24 hours.
Once this was dry, you find that the surface of that paint can feel dusty and a little rough, don’t worry , after a polish it all comes up good. Just don’t apply polish yet as you need to mask up the blue areas (or whatever colour you choose) on the dome, and getting wax or polish on these parts before painting can ruin the whole paint job.
It must be plastic Prep thou, as other paints won’t stick, or if they do they will flake off at a later time. Also the expansion of plastic in the extreme hot and cold will otherwise make your paint crack and fall off. I managed the head in one large can. After this dried, I used a Aluminium colour silver spray paint of the automotive type again. This took 2 cans, but applied in thin layers over a few hours and left to dry at least 24 hours.
Once this was dry, you find that the surface of that paint can feel dusty and a little rough, don’t worry , after a polish it all comes up good. Just don’t apply polish yet as you need to mask up the blue areas (or whatever colour you choose) on the dome, and getting wax or polish on these parts before painting can ruin the whole paint job.
After masking up the dome to protect the silver, key up the areas to be coloured with wet and dry paper and make sure that you get the dust off the dome before painting. A word to the wise, if you mask up with masking tape, check what the recommended ‘tape up’ time of your roll is. Some are 12 hours, some are 48 Hours, it just means that the adhesive on the tape will begin to bind if you leave it on too long, and may cause problems when removing from the dome if left on beyond the specified time. After spraying the areas blue that I wanted, and using 2 cans over the course of an afternoon, I waited only an hour or so and then carefully started to remove the masking tape as I did not want to leave it on for that long. I was worried that if I let the paint set fully then I could cause un-straight or peeling edges when removing the tape.
Waiting for paint to dry…..; I thought it best to leave it for a week to let the paint harden property before going near it with polishes. When I did get to get back working on the dome, I found that T-Cut or Rubbing Compound on the Blue Sections worked wonderfully, creating a shiny smooth finish, it also took out any textures that looked like it has been sprayed. The Silver Aluminium sections of the dome – I used – as recommended by some builders – a tube of Silver Leaf Buffing Wax – its available in Hobbycraft, but it is imported from the states, so its expensive here in the UK . There is someone on Ebay who has it here in the UK priced around £7 a small tube. That’s all you will need – it lasts forever this stuff. You literally rub it on like a car way – and buff it off – creates a truly metallic finish, which will tarnish and you have to re apply the wax after a few weeks. My only issue is that it does not seem to ever fully dry, and no matter how much you buff it, silver will still get on your clothes and fingers. To look at it, it is awesome, for events and people touching the dome – not so good.
So back to the frame body and legs. I had already began to paint the frame with white wood primer, together with the legs, feet and hubs. I wanted to protect the wood as much as I could and also I could cover my wood filler mistakes. At his point I plugged in the Front Logics and actually felt that I was achieving something.
Tuesday, 22 February 2011
Legs started, a flower pot and a few vodka's
So whilst waiting for the dome to turn up I literally but an upturned plant pot in place on the neck of the frame to give me some idea of the height of the dome.
A bit of spray paint and some washers glued on to give it a resemblance to the R5's. Made me feel like I was getting somewhere to the 'coffee table' remark that Mum had mentioned to me on her visit ! I cut some 'hubs' out of ply to allow me to attach the legs. these were not perfectly round no matter how much I used the belt sander. But I had an idea for those later on. The Legs and Hubs were drilled and attached by carriage bolts.
Using printed templates i was once again cutting around I think what was 6 leg templates of 12mm Plywood, gluing them together and using wood filler and a band sander. I also did the same for the feet. This should make you giggle - what it looked like at the time.
One particular night in the garage after a few vodka's ( not working with machinery may I add ! ) I added some red to the flower pot for no reason whatsoever ( except the voices in my head ). It was never a serious or permanent thing, just an indication.
So, here he stood. Making slow progress. So - the day arrived, my fiberglass dome arrived, a little rough in places ( as described by the seller ) , a little thin in places, and little out of line in places, but it was 1:1, and something I could work with. so I was happy.
A bit of spray paint and some washers glued on to give it a resemblance to the R5's. Made me feel like I was getting somewhere to the 'coffee table' remark that Mum had mentioned to me on her visit ! I cut some 'hubs' out of ply to allow me to attach the legs. these were not perfectly round no matter how much I used the belt sander. But I had an idea for those later on. The Legs and Hubs were drilled and attached by carriage bolts.
Using printed templates i was once again cutting around I think what was 6 leg templates of 12mm Plywood, gluing them together and using wood filler and a band sander. I also did the same for the feet. This should make you giggle - what it looked like at the time.
One particular night in the garage after a few vodka's ( not working with machinery may I add ! ) I added some red to the flower pot for no reason whatsoever ( except the voices in my head ). It was never a serious or permanent thing, just an indication.
So, here he stood. Making slow progress. So - the day arrived, my fiberglass dome arrived, a little rough in places ( as described by the seller ) , a little thin in places, and little out of line in places, but it was 1:1, and something I could work with. so I was happy.
Dome....dome ....DOME !!!
So, I start having a look at the head or Dome or R2D2, will I be able to make one? Aquire one from someone? There's a lot of builds that start with things such as Planters and other dome cooking bowl ideas. I was immediately drawn to one of the part runs which was the Darren Murrer 300mm Laster cut dual layer Aluminium dome. Probably if not the best on the market. And also an expensive item. But worth it if you can afford it ! Hastily I signed up on a part run, that was about to commence - The dome was around 600 dollars if I recall, plus shipping and plus import tax, and before long - its one of those items that you have let slip through your fingers. This item alone, no matter how much i wanted it was beyond what i could spend, and sheepishly, someone else was fortunate enough to get the one I had put my name on the list for. Now a word of warning from my mistake for new builders getting on part runs - don't do what i did - put your name down for one if you can afford to pay there and then on Paypal. Think carefully before committing to buy. The guys who organize these runs are spending their own time for getting you the perfect item for your build, the last thing they need is people backing out ( unless in a valid emergency in which a simple email direct to the Seller will suffice if not a phone call out of courtesy). The majority of builders are tolerant people, and don't need their time wasting. I hold my hand up to not completely understanding from the outset. Being excited to get what you want is not always the best situation to jump into. However - I will get one from Darren one day - when I can pay for it in one go. These Aluminium Runs can take several Months to complete and ship out - so start saving now !
However - there are alternatives available to the work of art shown above. There are Laser-cut Styrene domes around $200 from the States, and there are in some cases Fiber Glass Domes.
Now, a lot of the perfectionist builders will stay a million miles away from a fiberglass dome, but you pay for what you get. I fortunately managed to acquire one from in the UK for such a tiny amount -its embarrassing to even display the figure on screen, lets just say that I assumed it was a Proto-type. I managed to acquire it from Ebay, and I will mention Ebay do's and don'ts in a future post , entitled 'Ebay Bits Yay and Nay'
Now, a lot of the perfectionist builders will stay a million miles away from a fiberglass dome, but you pay for what you get. I fortunately managed to acquire one from in the UK for such a tiny amount -its embarrassing to even display the figure on screen, lets just say that I assumed it was a Proto-type. I managed to acquire it from Ebay, and I will mention Ebay do's and don'ts in a future post , entitled 'Ebay Bits Yay and Nay'
A few days later of reading..........Wood Frame Construction
After a few days of studying the Yahoo R2D2 Builders Club files / photos/ Blueprints and subscribing to their mail , I have downloaded some CAD Drawings and PDF's. The primary drawings here taking my interest are the 'Senna Wood Frame Plans', Named after the Builder who designed this particular framework suitable for wood, I take the drawings into my work to see if they will let me print them off at 1:1 scale. I should point out that during the days it took me to absorb so much information, I had the choice of going down the expensive 'Full Aluminium ' Build, which would take a lot lot longer and a lot more cash, as these parts and frames are usually produced in 'Part Runs' and you can be waiting months for the part, and also , most of the production of these parts are made in the USA, so the cost of the part, the postage, and the unwelcome 'Import Tax' usually makes these items far too expensive, and so I decide that I want to build a budget price full scale R2D2. So, wood it is. I also decide that my R2 will be a static model, that i have no intention of having it move under Radio Control, just a couple of lights and I will be happy. Its funny how things change in time, but more of that later.
Back at work, and the kind folk I work with, after humoring me a little , print off the Senna frame templates, which I take home, and after a visit to the local DIY show, glue the templates onto some Plywood, of varying thicknesses, but 12mm springs to mind. If you decide to glue paper to wood to allow you to cut around the template - used wallpaper paste and let it dry. It makes it so much easier to remove the paper later on !
Now after a couple of evenings, I have all the parts for the frame. But its clear that if I want this to be glued and screwed properly then I cant rush it, hence only a few bits per night should be attempted to be stuck into place. Also I found out that the two main body uprights, that will later support the hubs of the legs, unless these are exactly 90 degrees, and parallel to each other, they will later throw the legs out of line - so pay close attention at that stage. Heres a couple of pictures of the frame being assembled.
I did all the cutting with a cheap Jig-a-saw, which was not much cop. I also managed to get trough a packet of blades, and also employed the use of a router. Not something I had done before, but a bit scary at first. Please use proper eye & respiratory protection, as the dust still gives your throat the feeling of sandpaper, your eyes sore, and the smell of cut / and burnt wood lingers on you until your showered ! Its also noisy, so protect those lug-holes ! Don't worry if the fit of the wood is a little loose and gappy, with the use of the forgiving wood filler and a band sander or regular sand paper, you can tidy up many mistakes. So - you have something that looks similar to the above?
Its at this point I present my frame to my mother, with the customary 'Ta-daaaa!!!!' To which her reply is ' why are you building a coffee table?' Off to another great start !
Looking back - I would recommend looking through the images section of the Yahoo Club and Astromech.net files for photos of the other club members frames, seeing is believing, and helps with the jigsaw puzzle that will later be R2's Body.
Back at work, and the kind folk I work with, after humoring me a little , print off the Senna frame templates, which I take home, and after a visit to the local DIY show, glue the templates onto some Plywood, of varying thicknesses, but 12mm springs to mind. If you decide to glue paper to wood to allow you to cut around the template - used wallpaper paste and let it dry. It makes it so much easier to remove the paper later on !
Now after a couple of evenings, I have all the parts for the frame. But its clear that if I want this to be glued and screwed properly then I cant rush it, hence only a few bits per night should be attempted to be stuck into place. Also I found out that the two main body uprights, that will later support the hubs of the legs, unless these are exactly 90 degrees, and parallel to each other, they will later throw the legs out of line - so pay close attention at that stage. Heres a couple of pictures of the frame being assembled.
Its at this point I present my frame to my mother, with the customary 'Ta-daaaa!!!!' To which her reply is ' why are you building a coffee table?' Off to another great start !
Looking back - I would recommend looking through the images section of the Yahoo Club and Astromech.net files for photos of the other club members frames, seeing is believing, and helps with the jigsaw puzzle that will later be R2's Body.
Not Long ago (2009) , in a Galaxy.......real close........
February 2009 brought snow , snow and more snow to most of the UK. With with travel being a 'only if you must' many of us enjoyed a few days at home, enjoying the winter wonderland that was home - in Milton Keynes, Buckinghamshire, UK.
The kids school was shut, and naturally building a snowman was the logical choice for the day. Hence Huggie the Snowman was created.
A few days later, and the freezing conditions were easing up - and Huggie was now becoming a 5 and a half foot phallic symbol in the middle of the garden as the sun began to melt away at him. Strangely enough he held in there for a couple more days until half of this 'snow chap', came tumbling down. Half left, what could i do with 2 mins of my time to make this 'stump' look a little better? Of course - Turn him into the roughest ever produced R2D2. Well - I am no sculptor'er, but it did the job, and in the back of my head a very dim bulb tried to light.......
Another couple more days and we are snowed home again. This time I don't want to go out in the cold, but decide to change my son's Laundry bin into a R2 D2. Sprayed the dome silver, added the blue bits, and some lights, and yeah , it ....looks, ......very tacky......but he loves it. So now I am thinking - I bet I could build a full scale R2D2, just like in the films. So away I pop into the land of Google, to look at pics of R2s, and before you know it I find ' the "R2D2 Builders Club', a club stared by a few like minded individuals, and with the agreement of Lucas film themselves, that these guys and girls can be allowed to build their own likeness of R2D2 and other Astromech droids , providing that these builds are for their own private use, and not for resale or profit. The Yahoo mail group itself is free, as are the access to many blue-prints and photos / tutorials. To a new builder....its Aladdin's Cave. But there are also links to sites such as Astromech.net and Droid factory - all of which have more information that you ever could dream of when it comes to building a Droid. A quick search on You-Tube finds the videos of many builders, mostly in the USA, and the majority of which are far superior to those used in the Original Star Wars Movies.
The kids school was shut, and naturally building a snowman was the logical choice for the day. Hence Huggie the Snowman was created.
A few days later, and the freezing conditions were easing up - and Huggie was now becoming a 5 and a half foot phallic symbol in the middle of the garden as the sun began to melt away at him. Strangely enough he held in there for a couple more days until half of this 'snow chap', came tumbling down. Half left, what could i do with 2 mins of my time to make this 'stump' look a little better? Of course - Turn him into the roughest ever produced R2D2. Well - I am no sculptor'er, but it did the job, and in the back of my head a very dim bulb tried to light.......
Another couple more days and we are snowed home again. This time I don't want to go out in the cold, but decide to change my son's Laundry bin into a R2 D2. Sprayed the dome silver, added the blue bits, and some lights, and yeah , it ....looks, ......very tacky......but he loves it. So now I am thinking - I bet I could build a full scale R2D2, just like in the films. So away I pop into the land of Google, to look at pics of R2s, and before you know it I find ' the "R2D2 Builders Club', a club stared by a few like minded individuals, and with the agreement of Lucas film themselves, that these guys and girls can be allowed to build their own likeness of R2D2 and other Astromech droids , providing that these builds are for their own private use, and not for resale or profit. The Yahoo mail group itself is free, as are the access to many blue-prints and photos / tutorials. To a new builder....its Aladdin's Cave. But there are also links to sites such as Astromech.net and Droid factory - all of which have more information that you ever could dream of when it comes to building a Droid. A quick search on You-Tube finds the videos of many builders, mostly in the USA, and the majority of which are far superior to those used in the Original Star Wars Movies.
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