Wednesday, March 30, 2011
I have to do the exact same thing to the other side tomorrow. All this because I looked at the paint and wasn't happy with the grinder marks you could see under the paint. Now all this work is involved over cosmetics. Being picky can be very costly on how accurate you want your droid to be.
Posted by red UFO at 6:02 PM
Tuesday, March 29, 2011
Progress! I can see a few minor spot that need more sanding or filler. Next up is to install the footdrives and tweak the motor so the battery box fits the best. Then drill a couple of holes and fasten them together. I'll hold off on painting until I have the hoses installed
In a couple of weeks this droid should be done, but didn't I say that two weeks ago? I keep forgetting I still have to mount the side plate and its details.
Posted by red UFO at 5:15 PM
Monday, March 28, 2011
The styrene dome for R2-Q5 has arrived by UPS. A few panels shook lose but its in good condition. Tomorrow I'll olanto take the dome panels and remove them. This dome will be painted black and some parts copper. I'm really looking forward to doing this. I have something like 6 weeks before Phoenix Comicon 2011 to get BOTH droids ready. R2-D5 is nearly done, aside from finishing the ankles and feet. Hopefully I'll be able to drive R5 around, if not then oh well there's always next year!
By the 2012 Phoenix Comicon we should have 6-8 finished droids in the Phoenix region.
The bottom part of the dome fits good. The top don't fit at all. I'll need to cut the inner dome in half so each side fits as tightly as possible. So far in my droid adventures I haven't done much work on the domes and soon I'll be doing atleast 3 domes almost one after another.
The feet and battery box are in hurry up and wait mode. The 2 layers of JB weld and sand are going on. Then I'll use glazing puddy and sand that more. Sometime this weekend the ankles feet and battery boxes should be ready for paint. Then R5 should be on 3 feet for a while.
Posted by red UFO at 4:42 PM
Sunday, March 27, 2011
Then I make some ankle locks for my U channel. First I made a test piece out of cardboard, then copied that to the aluminum flat bar.
Now the bad. You're looking at one of the aluminum legs on R2-Q5. I was sanding out the grinder marks and the leg cracked. At first it wasn't too bad but as I was mounting the ankle on it it broke apart more. Time to stop. Either this has to be rewelded or I need new legs. Poor Q5 and its setbacks. This won't deter me very much. I'm very determined and will keep on going. The dome for this droid will arrive next week and I can work on that instead while I ponder over this. This droid probably won't make it to 2011 Phoenix Comicon now.
Posted by red UFO at 3:09 PM
Saturday, March 26, 2011
The last body piece on R5 is now installed finishing the look of the droid. Now I only have the feet and battery boxes to work on. Then he's basically complete except for future electronic work that upcoming.
Today I mounted the JAG ankles to Q5's leg. I had to drill my own custom holes in the leg and get 2.5 inch 1/4 bolts to go through both sides of the leg. I got the idea from Paul's R2-D2.
I didn't like how the painted legs turned out on this set. I didn't sand them and the result is tons of marks you can see through the paint where the grinder was used. So I used a sander and removed the paint and sanded all the grinder marks off 1 leg and got half of the other leg done. My hands go tired of the sanding so I called it a day. I think I"ll get around to sanding and priming these ankles soon.
Posted by red UFO at 3:44 PM
Wednesday, March 23, 2011
Today I finished my upper center vent. I did what Tiny P suggested as always. I super glued and then JB welded the vents into place. Then filed them carefully and slowly with a hand file until the tightly fit into place.
While I was cutting out my other battery box the welds that hold it together cracked. I didn't have a choice and had to cut out of the side that was welded. Check which side is welded before you cut yours. I suggest using a dremel with an easy lock cutting bit. I messed up and used a jigsaw and it vibrated it apart as you can see. So I'll have to now fix this weld with some steel plates.
Next I need to either grind the hell out of these nuts to fit inside the battery box or tape the or do both.
I'll first try to tap it. If that don't work I'll grind down my nuts.
Tom is working on a wiring diagram for this 15 channel RF remote. This is good for things like turning on and off LED lights. I don't see how you can hook this up to run servos.
I whipped up the formula from Valcheck which ages your braided hoses from a nice shiny copper to a more darker look that's more accurate.
Posted by red UFO at 4:50 PM
Monday, March 21, 2011
Tiny P. said this wouldn't be much fun cutting out the holes and trying to get them to fit around the NP motors. He was right. You have to do this alittle bit at a time. Very mundane work.
I marked a line with the motor off showing the area you can't cut above. I was able to get 1 of the battery boxes to fit today. Take my advice and don't cut too close to that line. Mines right at the area where it might show where I cut it and need JB weld or some filler. I got really, really close.
Notice, you have to grind down both sides of the NP motor, plus it helps go grind down the lower part of the NP motor too.
This is how much material I had to remove to just barely get it to fit. It don't go on sloppy either. You have to push, pull and tug a few areas to get it to go on. I don't have time to make a perfect square hole right now I have comicon right around the corner.
Posted by red UFO at 4:24 PM
Sunday, March 20, 2011
'Squeaks' came by to inspect the work and sniff each part for something.
I cut out the hole I marked. With a test fit its too small to fit. Also the lower part of the frame is in the way. So, I'll need to take all the legs off and keep trying with the foot only to get this to clear the NP motor. I'll work on this more next week. Its a small job to take the batteries out of the droid, unscrew the middle foot and outer legs.
I spent most of the day on the JEDI control installing it. I hooked up the JEDI and it don't work anymore. It does the sounds, but the entire servo channel don't respond to anything. Plugging in a servo has no result. The dome motor no longer spins and a long shot on getting the Sabertooth 2x25 was dead in the water. I'm so close to driving him but so far away.
Posted by red UFO at 3:53 PM
Friday, March 18, 2011
This thing is big! He takes over the living room, which is pretty cool.
It took about an hour to repeat what took me 90 minutes yesterday. I was able to mount the JAG drive to my other foot and only have to cut once and then mount. Everything was flowing smoothly so I kept on going.
Now its put together I don't see how this is re-enforcing anything since it only attached the leg to the leg. LOL. I think maybe I should make a steel plate with 6 holes or something and have them screw into that. I dunno yet.
You'll need to use a round file inside the ankle so the copper bushing will fit in. You don't want to file too much so it slides in by hand. Just enuff that it starts to nest in each hole. Then push them together for the good solid fit.
So the 4 bolts are going through the spacer and then screwing into those other 4 inserts. I think if I add a steel plate to connect all 6 bolts. That will do a decent job to re-enforce the ankle to foot. R5 is top heavy so I don't mind some over kill in some areas.
I'm not used to having him stand so tall now that he's on all 3 feet. Now the real fun begins. I'm almost done with the basic assembly and construction phase.Soon work on the R2-D2 head that will sometimes a go on this droid. Lots of electronics work ahead. I also have Q5 legs and ankles that need to be put together and attached to that foot drive I put together last week. Soon that droid will be on 2 feet, since I don't have a center foot for it yet.
This took a lot of work, a bunch of money and a few drops of blood. But its worth every penny.
Posted by red UFO at 5:56 PM
Thursday, March 17, 2011
I disassembled the JAG drive and then finished marking the hold I need to cut. In some photos I've seen holes that are quite large. I'm going to take out small sections at a time.
Then I drilled 4 holes at each corner so I could fit in a jigsaw blade and cut out the hole.
Now with the rough hole cut I remounted it. Thankfully it don't quite fit and I have to trim more. I marked the area where I need to trim. It seems like I'm quite close. I'd rather have this too small than too big.
I like my laser guided jigsaw but this curved area won't work with it anymore. Time to break out the dremel and the new easy lock cut off wheel and trim this off in no time.
Wow! I can't believe it. After 2 cut it fits! That almost never happens. Usually I screw something up. The real test will be to see if the NP motor fits.
The NP motor fits! I'm on a roll now. I'll file this hole into a nice clean square later when I work on the battery boxes.
A closeup. I'll need to file the bottom part some incase I need to do later tweeking to adjust the motor into proper position and the make sure the drive belt is tight.
Here is a look at the other side. I don't know how many months I dreamed of getting this far in my build. I'm almost there to the point I can get R5 to drive!
This entire process took 90 minutes. 1 done and 1 to go. On Friday I'll do the other foot and have both feet ready for the first test.
Then I got to work on my back door, which of course never ends. Today I mounted the super 1.5 inch magnet on the back Power Coupler. I don't dare put the same size magnet on the droid frame. It would rip off that Power Coupler if I did that wrong.
The other side this attaches too I decided to use two .750 rare Earth magnets. But later learned 1 magnet is pushing the main magnet away and I need to order another set of these. Thus, this project won't end any time soon. Someday my grandkids will take over this blog and update with their progress.
I also did some painting. I took the new bars that arrived the other day and masked then, primed and painted them black.
Then they got 2 coats of copper on them. After 2 days of cooking in the hot AZ sun they'll be ready to touch and install without fear of leaving finger prints on them.
If everything goes right on track sometime around Sunday I might be seeing R5s first steps. If this droid don't fall apart he'll be driving around the next Phoenix Comicon.
Posted by red UFO at 5:43 PM