Building my own full size (1:1 scale) R2D2

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Re: Building my own full size (1:1 scale) R2D2

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Re: Building my own full size (1:1 scale) R2D2

Postby casper » Fri Mar 03, 2017 7:50 pm

Dont envy you sanding the parts Roy the dust must awful but you've made a great start :clap:
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sat Mar 04, 2017 12:04 am

Thanks Casp,

I've had the dust under full control, all cutting, sanding was done outside. I made sure that I wore a face mask and goggles. I've also got some full disposable protective paint suites. Fibreglass is not considered to be harmful, only an irritant, but I took precautionary measures anyway.

I decided to test fit and cut out any panels first, this will give me a clear indication which parts are left visible for sanding, as it seems pointless in spending time to sand the fibreglass by hand if it was not going to be seen.
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Fri Mar 24, 2017 9:20 pm

I've done some more cutting, there is no more to do at this point, but there will be more to do later when I fit the motors and decide how 'm going to fix the legs, especially if I going to make it go from 3 legs to 2

Image

All the parts test fitted,

Image

Image

Image

Image

The kit didn't come with dome bumps, so I drilled some holes in the dome where they are suppose to be and I fitted some coach bolts


Image

My next job will be for me to sort any imperfection on the moulded parts by either sanding or using filler.

To be continued...
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Re: Building my own full size (1:1 scale) R2D2

Postby steve131 » Fri Mar 24, 2017 10:40 pm

Good work Roy.
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Re: Building my own full size (1:1 scale) R2D2

Postby Mark » Sun Mar 26, 2017 8:57 am

Coming on nicely
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Re: Building my own full size (1:1 scale) R2D2

Postby Mark » Fri Mar 31, 2017 5:57 pm

I stumbled across this Youtube channel - I don't know if will provide any help or not.

https://www.youtube.com/watch?v=Uw9isRLIp0M
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sat Apr 01, 2017 10:15 am

Cheers Mark,

I've have seen that one ages ago when I first did my research into building one.

I've spent the last week sanding, washing and filling any imperfection in the parts. I've got sore fingers now as it wasn't always possible to use a sanding block, especially in all the nooks and crannies. Still plenty more sanding and filling to do. I will need to give my fingers a weeks rest to heal before I do any more sanding. It's really coming along nicely now and all the parts are becoming very smooth to the touch. I'm very pleased with the results so far and hopefully I might be able to post some photos later.
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sat Apr 01, 2017 8:46 pm

The imperfections in the mouldings were due to air bubbles in the resin. I dug these out with a screwdriver

Image

I filled all the imperfections with some Isopon 38 car filler. Here is just a few of the items that got filled

Image

I will sand the items again, wash them and refill any imperfections that I missed or not happy with.

I drilled out holes in the battery box's and feet to accommodate the hose connectors.

Image

The inside of the feet were solid resin at the top, so to accommodate the motor frame/bracket that I will make at a later date, I used a router bit in my drill. There are two parallel channels that I routed out, very hard to see in the photo. These will also allow me to fit a nut on the inside for fixing the feet to the legs. I might need to route these out more at a later date.

Image

If I was to go for a simple static build, then I could quiet easily finish this build by the end of the month. However, as I plan to fully motorise the build, it's going to take me a while to complete, especially if I plan to make it go from 2 legs to 3 and back again. I do have a PDF instructions on how to do this.

I will leave painting to the very last as I will need to drill and cut out more of the fibreglass moulding when the time is right


To be continued...
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Re: Building my own full size (1:1 scale) R2D2

Postby wingnut » Sun Apr 02, 2017 3:43 pm

Hello Roy, that looks like hard work mate ! just out of interest have you thought about servo's, motors and tracks ?
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Re: Building my own full size (1:1 scale) R2D2

Postby casper » Sun Apr 02, 2017 4:09 pm

Doing a great job Roy, always fancied having a go at a full scale R2D2.
Some of the build videos on you tube show the inside mechanisms and boy do they look complicated :ugeek:
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sun Apr 02, 2017 4:53 pm

wingnut wrote:Hello Roy, that looks like hard work mate ! just out of interest have you thought about servo's, motors and tracks ?
Cheers Mike.


Thanks Mike,

I've done a lot of research into this, I brought my Dremel and router a few years ago with building one of these in mind. I've a whole list of parts and diagrams saved to my laptop ;)

casper wrote:Doing a great job Roy, always fancied having a go at a full scale R2D2.
Some of the build videos on you tube show the inside mechanisms and boy do they look complicated :ugeek:


Thanks Casp

I've seen some amazing R2's on line. It really depend on how much you want the R2 to do and how much time and money you want to put into it. I'm going for a basic build apart from the 3-2-3 build. I've seen builders have warping problems with the doors that open up. I've decided not to have any doors or dome pies opening up.

I plan for my R2 to do the following

Motorise feet
3-2-3 action
Dome rotation
Dome lights
Utility arms movement
Sound
Maybe a projection of Leia
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Fri Apr 14, 2017 7:53 pm

I've purchased some attachments for my Dremel including a Flexible drill shaft, Dremel holder and 30 diamond Dremel graving bits

This made using a Dremel easy to use with more control.

The body is not accurate and is missing a groove in-between the utility arms ports. So I engraved a line out

Before

Image

After

Image

I also use the Dremel to engrave some of the grooves on the dome that were hardly visible. I also used the Dremel graving tools to tidy up any parts that a file or wet and dry paper couldn't reach, especially in all the tiny nooks and cranny's which had resin knobbly bits that needed to be remove. You can see one of the feet and dome in the next picture that had been tidy up.

Image

The rain stop further work on the central foot.

Also when removing some of the knobbly bits, I came across some more air holes which will need filling.

With the time spent preparing the parts, they are really beginning to look very nice.

To be continued....
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Re: Building my own full size (1:1 scale) R2D2

Postby builder76 » Sat Apr 29, 2017 11:10 pm

Loved the film. Fascinating subject R2D2 . 1-1 scale wow. :whistle: :D
Great progress so far.Looking forward to more postings.

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Re: Building my own full size (1:1 scale) R2D2

Postby casper » Sun Apr 30, 2017 1:31 am

thanks for the links Roy ;)
"Maybe a projection of Leia" now that would be cool :)
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sun Apr 30, 2017 9:28 am

I've been working on the R2 over the past week, more sanding and filling, almost there with the preparation.

Your most welcome Casper

As for the projection, I have saved a recording of princess Leia that has been specially edited and available for the purpose of using as a projection. I'll email that to you.

I also looking out for the Deagostini build the R2D2 issue that contains the projector which may be useful to add to the R2. I also have purchased one of these pens, you should be able to purchase one cheaper if you search the internet a bit more

http://www.ebay.co.uk/itm/Star-Wars-R2- ... Sw5cNYGdAR
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Re: Building my own full size (1:1 scale) R2D2

Postby Mark » Mon May 01, 2017 4:37 am

Like the pen. I wonder if it's a good projection in the flesh ?
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Mon May 01, 2017 10:08 am

The pen projection is good, it's a static picture though. A moving pic would be better. Instead of fitting the actual R2 with a projector, I might use the pepper's ghost illusion to give the illusion that the image is coming from the R2 unit
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Re: Building my own full size (1:1 scale) R2D2

Postby Mark » Mon May 01, 2017 11:22 am

Just Googled Peppers Ghost. How are you going to use that effect on a moving R2 ? Can't work it out myself.
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Mon May 01, 2017 1:35 pm

With regards to the Leia projection, I'm currently keeping all my options open with which method I'm going to use, I might use more than one option so that I can choose which option is the best one at any time.

Which ever option I use, the R2 will need to be static at the time of projection and he will also need to be position in order to get a good projection whether the projection is to be projected against a flat surface or glass. So for the Peppers ghost illusion, I will have to move R2 into the appropriate position so that he is facing the glass and then I will have to switch on the mini TV screen to reflect off the glass.
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Re: Building my own full size (1:1 scale) R2D2

Postby royjess » Sat May 06, 2017 3:31 pm

The last of the Isopon 38 filler and sanding done. The ribs on the bottom of the skirt wasn't straight, it look like they came out of the moulds crushed looking. So I build these back up again where they should be with the Isopon.

Image

The centre foot had some of it lines missing, so I engraved these in.

Image

Not much more that I can do for the moment.

I've need to raid our bank account to continue....
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