Build Entry #5 8/15/2014

Not as much progress this week as I'm trying to complete the parts I've started.  I had to trim the shoulders holes in the skin they were a little small but now they fit. 

I'm working on finishing the task of skinning the arms. working on slowing down to make each part a precise as I can.

I acquired some aluminum sheet metal and fabricated my first test piece a coin return detail.

I drafted myself some plans to cut out the Side and Pocket vents 

we'll see how they work out.

 I also began construction on the skirt section.  Its nice to have room to work on a couple of projects at a time, glue one up and let dry while you fabricate parts for another.

Build Entry #4 8/8/14

So this week I scored a major piece, a Vacform dome from the C and D run.  The seller was kind enough to pencil in the panel lines from an AL dome.  A major amount of layout work was saved, I still have to cut out the panels by hand.    

I also finished installing the outer skins, front and back. 

I also completed attaching all the false door fronts.  Small neodymium magnets were helpful in holding the pieces in place while gluing

I also started the process of skinning the legs

Wrapping the Shoulder hubs in AL sheet, I trimmed it the same way I cut the plastic - score and snap, made a nice clean edge.

Build Diary Entry #3 - 8/1/14

  This week I started cutting out the body skins.   The inner-skins have been installed and the seams glued down and reinforced.  I completed building the second leg.  

  

  I was also able to purchase a 2 layer vacform R2 dome.  It's not cut so I'll have to hand cut the panels out but that was major piece to add.  On to the build photos

On to the build photos:

The first layer of skins cut out

Glued in place

Rear outer skins cut out

Rear inner skins glued in place

Cutting out the outer skins

I also built the second leg

Much easier the second time

Total of parts built:
Frame - finished
Innerskins - installed
Outerskins - ready to mount
Legs - ready to skin
Shoulders - ready to skin with Aluminum

Testing the fit of the outer-skin

Build Diary Entry #2 - 7/25/14

Worked on the shoulder hubs in a late night session in the garage with Spaceballs playing on the ipad.  I also began on the legs.  I tried to order the foot motors this week but they are back ordered.  I'd like to have them on hand when I build the feet.

Shoulder Hubs:

The next moring after the glue dryed, I drilled out the bolt holes and countersinks.

  Test fit it all looking good to me.

 Test fit - its looking good to me.

 Skinning the hubs

Some scrap aluminum my Dad had at the shop to finish them off

Leg Assembly:

Test Fit: Still some work to do, to get the front plate on and square

Build Diary Entry #1 - 7/18/14

So I want to document my build of R2-D2.  I'm using the Styrene plans from Astromech.net and gleaning all the information I can from friends build's and build threads on the astromech.net forums.

My end goal is a RC controlled droid with dome spin, lights and sounds.  I'm planning to have motion on the utility arms in the future.  I will try to let the photos do most of the talking.

So step one was to mount my router in a table to cut circles out. I made this from scrap wood in the garage.  It was Wyatt’s idea to mount it on the side of my existing work-bench.

I'm lucky to have a plastic supplier in town so I picked up 4'x8' sheets of 3mm and 1mm Styrene and Weldon 3 glue.

Starting to lay-out parts

 I cut the circles with my jigsaw. yes it made a mess of sharp plastic bits.  I shouldn't have done that in flip flops

First days work at cutting out the verticals for the body frame

 Routing out the body frame rings, yes its a big mess.  I ended up adding cardboard to help corral the little bits. 

Assembly

 First Ring

 I used L-brackes I had squared up on my carpenters square to help keep everything in place

 The Parthenon

 After building this is the materials I used to build the frame

1. Square to keep every thig lined up
2. Sandpaper stapled to a block to sand the plastic to a true 90
3. Metal L brackets
4. Tape

The base is two layers

 The nerve wrecking job of rounding over the legs - I think I only messed up one leg