Do You See The Pattern Out On The Fringe???

Tonight I cut out the legs. I am not finished yet. The first picture shows the pattern sitting on top of a 3/4 inch birch pine rough cut of the inner board in the leg. I actually started cutting the 3/4 inch pieces for the leg first but discovered that I only had a 1/2 inch guide bit for the router. I actually had looked for a 3/4 inch guide bit at Lowes when I was there, but all they has was the 1/2 inch. I am thinking I will head to a local hardware store to see if they have one.

That however was not my first complication. First, I cut the pattern out of some cheap 1/4 inch plywood I had lying around. This would not have been a problem, except that I had cut the blue print out too small. That when I measured the pattern to check myself, the pattern came up short.

So I recut the second blueprint I had printed out and recut the pattern. Correctly this time. My second obstacle was the 3/4 inch bit I didn't have.

Because I don't have the router mounted on the bottom of the table, the pattern had to be clamped, then flipped with the pattern on the bottom and the router on the top. This presented difficulty in seeing where the router bit was a forced me to trust the pattern. It worked though I got tons of saw dust in my eyes while trying to see where I was cutting. That was with safety glasses.

Never-the-less, you can see the final product and while they still need a bit of work, I am pretty pleased with how they turned out.

Well, I'll keep you all updated.

Peace,

Scott

Frame Glued and Leg Prints Printed

With the help of my awesome daughter, the frame has been glued... and weighted ...and taped..... We'll see how it all holds together when blocks are removed and the tape is gone. I do want to reglue under the top once the bottom is dry.

Alse ran to staples today to print out two copies of the leg prints. Cost me 30 bucks. They couldn't print the CAD files, but the pdf version printed fine when tiled and is to scale. All I need to do is piece it together.

Brief but that's it for today!

Scott

Frame done! Glue factory here I come!

Finished the Frame! YeaaaaaH!

Ok, Ok. So I know my work is only beginning, but after working on the frame for about two weeks, I feel like I have accomplished something.

So the pictures show the frame assembled without the top and the bottom cut out. When I was convinced everything fit together, I tore it apart, cut out the top and a bottom. In the next photo I have the frame reassembled after cutting out the top and bottom. I slide the skin down over it but it was a smidge too tight. So I had to slice the duct tape.

The last picture is of it wrapped around.

The next task I think I will tackle is the legs. Well, I still need to glue the frame. Planning that tomorrow.

Peace.

Scott

Still Framing, But Getting Close To Glue...

THE FRAME IS ALMOST READY! I need to cut out the center of the top and base. I need to recut one of the struts that shattered on the bottom.

But the skin fit perfectly. I duct taped the skin together so I had an idea as to whether the base, center circle, and top were the right size. I fit each as I cut them. Then after those three were cut, I assembled the frame using the struts from yesterday and the leg supports. My daughter helped hold the frame together since I was assembling it with out glue. In the assembly of it, I decided to recut the C strut. Never-the-less, I could use it for the moment. Everything went together well.

The frame stood a half inch above the top of the skin, but only because I had not made any cuts into the top. I didn't have skins quite lined up right, but because they were so snug, I couldn't really turn them.

But the good news is that, pending how the cutting goes tomorrow, I could be ready to glue Tuesday. I'm hoping anyway.

Cheers,

Scott

The Frame's Together But Not the Frame I'm Looking for...

Today, as one can see
via the photos, the frame came together. Really it was my first attempt at a frame so I was excited. It let me know that, yes, I can do it. On the other hand the frame together, clearly showed some of my measuring flaws and brought me to the realization that at least some of the frame I was going to cut again. Also, some of the plywood quality I used was older and weathers and thus split when I cut it. This weakened the stability of the frame. Core in this idea, and as someone from the Astromech dot net once said, the more time and care you take in cutting the frame, the better it will go together.

I don't have pictures of it, but I already began to map out the base, center ring, and top. This time I actually used to prints to establish the circle and marked out the slots from the get go. I have also decided that as each one is routered out, I will place the skins around them to make sure the are the right size. I have also decided that I will cut the notches and slots before cutting out the centers of the rings. The wood I am using is a stronger plywood and not as aged. This should also help.

I don't know if I will completely rebuild the frame, but I will at least start here. I might have to recut a few of the struts as well.

Cheers.

Scott

The Ankle Bone Connected to the Leg Bone...

So...progress continues and as I type this, I do actually feel we are making some headway. Yesterday, was spent marking the wood with the patterns from the R2D2 Builder's club. Today was spent cutting some of the supports out and notching them. Also cut out the center circle and notched it. You can see some of my progress in the attached photos.

I made a few mistakes; I think they will be recoverable. One of the notches went wider than I intended. Because I was trying to cut costs down, I used plywood that was aged and at parts weathered. Because of this, one part of the ring split as I was routing it. The ring is still whole; just a bit thinner at that point. I am gluing parts of the wood back on, and will reinforce it. I can always re-cut it if need be. Went out to Wal-Mart and picked up some wood glue and wood putty.

But it actually looks like the pictures of the frame I have been seeing. I began seeing how it all fit together while I was reading through M. Henrichs R2D2 frame Notes.

Anyway, my daughter and I had fun doing this today, though she finds it hard to see how this will eventually be R2D2.

Till next time, cheers.

Scott

The Cutting Continues....

Today, I trimmed the base and the cut the top and side supports. That was this afternoon. This evening I returned with my daughter who helped me cut the spokes and rib circles. Again these are basic cuts and the centers have not been carved out. Spokes have not been notched or cut down. also think I need to cut two small pieces yet for the frame. But progress none-the-less.

Scott

Traveling through hyperspace ain't like dusting crops, boy! - My attempt of cutting a base.

Well, I did start on the base today. It was a hugh learning curve. Bought two C-clamps from Lowes. Should have most of the tools I need. I think I can bum the rest off my dad. :-)

Huge....did I say huge? Huge learning curve today. If I ever routed anything it was 20 years ago in high school and I don't think I ever work with the circular tool attachment. Thought I could trust the measurements on it, but I couldn't.

Routed it twice and got close to an 18 inch diameter on one base. Took me a hour to accomplish. Again wasn't real sure what I was doing.

So tonight I brought the base piece I had cut out and measured it 18" across all over the place so I could see where I needs to shave off. Then I measured for the top as well. Hope to have pieces cut out by tomorrow.

Scott

Now Where Do We Start? Dome and Frames arrive.

So I arrived home from vacationing with my family in the mountains to find the aluminum skins I ordered and the Dome I ordered sitting on my front porch waiting for me.

I wanted to tear into them, but left them boxed as I helped unload our luggage. After supper, I unboxed the head and my sun shouted witrh glee, "It's R2D2's head!" He wanted to build it right away. Unfortunately for him there was no building that night, only unboxing the head and skins and carrying them out to the work area in the barn.

Looking at everything laid out is a bit overwhelming. Like "Now what?" I know tomorrow I am hoping to make at least a rudimentary attempt on the frame. We'll see how it goes. I have a ton of yard work, etc, I need to do as well.

Also need to pick up some clamps and perhaps a belt sander.

Scott

Cobbled Together From Discarded Scrap...and, Boy, Did I Make a Mistake?

Well, heading camping with my family and my extended family this weekend, so will be my last post till next week. The reality is I won't always post everyday anyway. I find I initially do a real good job at blogging and then I get distracted or something. I pledge to do better.

Today I went to Office Max and got the Senna Frame Prints (by M. Davis) printed out. The good thing was I got two copies for about $6.60 a piece, which seems like a good deal. The bad thing is I am uncertain if I can use them since the frame is measuring slightly under the 18" diameter I was told was needed. It could be a few things: the prints, though printed at full-size are measuring small, the measuring device I used at Office Max was off (such things do happen), or that the prints are right and are accounting for the skin. I am trying to find out from the forums at Astromech.net.

I then went to Home Depot to purchase a Roybi Router. I figured since I wasn't planning on doing much routing beyond my droid, that I didn't need something real expensive, not to mention that I already spend over a grand so far. I also looking for the Milescraft Router Guide which would allow me to rout a perfect circle. Home Depot did not have it, so I ended up going to Lowes, and they had both. So I picked them up, along with three bits. Total bill for those was $125.00.

I feel somewhat armed now and ready to tackle the frame next week, pending my plans are correct at least. Every thing is now waiting in my shop, and I am waiting on the parts I ordered.

So cheers for now.

Scott

C-3PO: I beg your pardon, but what do you mean, "naked?" [R2D2 beeps]

Haven't had time to do much more on the work area. I need to pick up some equipment to make the frame. I think that is my next step. And probably my next major purchase.

Actually, it was funny. Yesterday I finished blogging about what I did regarding my droid and I had just finished writing about purchasing an alluminum skin if one became available, and low and behold one did; it was still in the box none-the-less. Really there is not a lot more I can get without actually building the wood frame of the droid. So I grabbed it for around 230 bucks (that included shipping).

So now I need to closely examine the frame and figure my next course of action.

Cheers.

Scott

It's nothing, sir. Merely a malfunction, old data.

So I bit the bullet and ordered the dome and rocker as I wrote yesterday. Now what?

One of the things I did over breakfast was show my daughter what I had purchased. She knew instantly what it was (thankfully). I told her I was thinking of setting up my workshop to build the droid in the barn, and she suggested that I use a stage area (we have used the upper area of the barn to conduct fund raisers for Haiti) to lay out my parts. Excellent idea. Later this afternoon, I
swept the area, laid out some saw horses, gathered some plywood, etc. Found a nice translucent jug that I pan on using for the Front PSI lens and the P5 Picture Panel. Got me totally stoked.

The other thing I did was buy some of the readily available dome accessories on Astromech.net.









I purchased a Resin Radar Eye, 3 resin Holoprojectors, and the resin logic surrounds. The other thing I bought was the Radar Eye Lens. In retrospect, I could have save myself 20 bucks off of a 150 dollar bill if I would have read the Wiki on the Astromech site. There is a cheap solution using the curved edge of a 2 liter Coke bottle and some black paint that would have served me fine. I am sure down the road, there will be things that twenty dollars could have gone for.

So why buy these parts now? I suppose I could have waited until the dome arrived, but something about fleshing out the externals of the Dome once it arrives, has me excited. I think it is because it will begin to take the shape of an R2 unit.

The only other thing I would like to get is an aluminum skin if one becomes available.

Cheers

You've taken your first step into a larger world.

I bit the bullet a tonight and actually committed to at least trying to build and R2D2 Astromech Droid. Really until the cash is laid out, one can talk about building droids and being interested in them all they want. Now there is no turning back.

My commitment started with the purchase of 300mm Cole Horton aluminum 2-layer R2 dome complete kit (it apparently has been sanded but needs more work, and the panels are cut out) and the Rockler bearing (makes R2's head swivel).

The Dome I purchased is to the left. The bearing is below on top of a PVC reinforced tube which I considered purchasing, but after talking to PixelFiend and Tom Dunlap, and looking at the blueprints, I decided to build the frame out of wood I have around the farm to cut costs.

Just to give you and idea of how quickly costs can mount, I spent a half of grand on the aforementioned parts, and that is a good deal. 8-O

So what made me want to build the dang thing anyway? I blame Ed who I met at Shore Leave 31 and then the following year at Shore Leave 32. Both years I interviewed Ed for a podcast I run called The SciFi Diner Podcast. This year, however, after the interview, we sat and chatted for a good hour about his process of making his droid, what went into it, and ideas and pitfalls. (BTW you can find that interview here.) That got me thinking.

I was kind of looking for a project I could do with my kids, and this seemed like the perfect project that not only feed my geekiness, but also with the potential for all of us to learn together.

The next step for me was to join Astromech.net and browse around the forums, the Wiki, etc. I bit overwhelming since there was so much information! After allowing that overwhelmed feeling to pass through me, I began looking for a place to start. Many were saying start with the head or the body. This seemed like a good idea. I mean, can you imagine R2's head just staring back at you? Seems like a good motivator for getting the rest of the body done.

After introducing myself to the club, Greg (AKA PixelFiend) contacted me and said that he was probably one of the closest droid builders near me, and invited me down. So yesterday, I along my two children, took a trip down to his house to see R2D2. I was glad I did. I walked away with a lot of practical advice.

Well, it is late and I am tired. I will dwell more on what I have gotten myself into tomorrow.

Scott