Thursday, 24 November 2011
A Nightmare in the Garage!!!!
I was thinking a shift off work would result in massive moves on the building front. It has and it hasn't so let me tell/bore you with it.
The ankle plans were cut out and started to put together, except for the top cover. this is because I was toying with the idea about putting a tie rod in to keep the foot flat when in 3-leg mode. Whilst doing this I noticed that the groove on the leg was only just above the ankle - this made me look at pictures of R2 and see if this was right. The leg also had a MASSIVE amount of room when in the ankle - surely that can't be right!!!
That evening I nervously opened the laptop and file containing the leg plans. View magnified to 100% and a ruler showed about 15ish cm from leg bottom to the groove. A quick "Don't anyone touch the computer or else" was shouted to anyone listening - pointless really as even my daughter (assistant) ignores me - and out to the garage to check my measurement. "Nooooo!" I had 12cm, somehow I had cut out 2 legs at approx 75% size. A bit of a sulk that night and the next day back out cutting the styrene at 100%. The difference is unbeliveable.
Before I carry on with the leg, it was time to build a shoulder, so improvised circle cutter to the ready and away I went. This was so easy and in no time at all the right hand shoulder was finished.
A foot was then started, mainly to get the ankle onto while I worked out the tie rod for it. This was bolted to the ankle to help alignment etc. and then a bit off research over a bowl of soup at lunchtime. This revealed that no-one on their blogs has mentioned a tie rod, so just to get the build going I opted not to work it out and thus rebuilding the leg started again.
Its just a matter of finishing this leg and foot and repeating the whole process for the left leg but at least he will be a better size.
We have even thought of a name for our build, not too sure if its a droids name but ST-80. ST from Skye's initials and 80 from mine (AT). I have told Skye that have to personalise it if we use this name to make it different from R2.
The ankle plans were cut out and started to put together, except for the top cover. this is because I was toying with the idea about putting a tie rod in to keep the foot flat when in 3-leg mode. Whilst doing this I noticed that the groove on the leg was only just above the ankle - this made me look at pictures of R2 and see if this was right. The leg also had a MASSIVE amount of room when in the ankle - surely that can't be right!!!
 |
| Oh! Woe is me! |
That evening I nervously opened the laptop and file containing the leg plans. View magnified to 100% and a ruler showed about 15ish cm from leg bottom to the groove. A quick "Don't anyone touch the computer or else" was shouted to anyone listening - pointless really as even my daughter (assistant) ignores me - and out to the garage to check my measurement. "Nooooo!" I had 12cm, somehow I had cut out 2 legs at approx 75% size. A bit of a sulk that night and the next day back out cutting the styrene at 100%. The difference is unbeliveable.
 |
| Little & large |
Before I carry on with the leg, it was time to build a shoulder, so improvised circle cutter to the ready and away I went. This was so easy and in no time at all the right hand shoulder was finished.
 |
| Dry by morning. |
A foot was then started, mainly to get the ankle onto while I worked out the tie rod for it. This was bolted to the ankle to help alignment etc. and then a bit off research over a bowl of soup at lunchtime. This revealed that no-one on their blogs has mentioned a tie rod, so just to get the build going I opted not to work it out and thus rebuilding the leg started again.
 |
| That looks better! |
 |
| Deja Vue? |
Its just a matter of finishing this leg and foot and repeating the whole process for the left leg but at least he will be a better size.
We have even thought of a name for our build, not too sure if its a droids name but ST-80. ST from Skye's initials and 80 from mine (AT). I have told Skye that have to personalise it if we use this name to make it different from R2.
Monday, 14 November 2011
Revamped Shoulders & a bit of leg
A day off from work, and instead of cleaning the windows I opted to spend the time in the garage working on R2. ( The wife hasn't noticed the windows are still dirty - yet!)
I cut out the modified shoulder plates as per Dave Everetts mods, and drilled the holes out to 6mm. I then had the idea of using some plywood and mounting the router underneath to make the slots. (This has been done by others who follow Dave's plans.)
It worked a treat.
The shoulders were then glued in whilst I start glueing the leg braces etc.
I clamped all the braces together and filed square. Then with a 12mm drill in the bench drill, made the hole through the middle for the wire tube. I was using a piece of 15mm copper pipe as the tube, and didn't have any bigger drills - Hmmm!
Then in my one brainwave of the week, I remembered I had a step drill (?) this had a size of 15mm. Fantastic. The only problem was I would have to drill the braces individually.
This done the tube pipe was put in and glueing started, ensuring they were all square of course.
A spot of luncheon and a cuppa left me ready to carry on.
The legs shoulder braces were filed to shape - a small square out off a corner, and then more glueing. This was a tricky bit, as trying to keep them square involved masking tape for the first time. It wasn't to stop me singing along to the radio as the neighbours may have wished but to hold the braces square while the glue dried in the lovley damp, cold winter air of the garage!!!
This will do for the day, and so inside to cook dinner, bath Skye and update the blog. Followed by sorting out my R2 files, what plans need printing, sorting out skins and a dome for my xmas present. Its a busy life at times isn't it?
I reckon another update before the weeks out though!
I cut out the modified shoulder plates as per Dave Everetts mods, and drilled the holes out to 6mm. I then had the idea of using some plywood and mounting the router underneath to make the slots. (This has been done by others who follow Dave's plans.)
It worked a treat.
The shoulders were then glued in whilst I start glueing the leg braces etc.
 |
| New shoulder plates - hopefully right way round!! |
I clamped all the braces together and filed square. Then with a 12mm drill in the bench drill, made the hole through the middle for the wire tube. I was using a piece of 15mm copper pipe as the tube, and didn't have any bigger drills - Hmmm!
Then in my one brainwave of the week, I remembered I had a step drill (?) this had a size of 15mm. Fantastic. The only problem was I would have to drill the braces individually.
This done the tube pipe was put in and glueing started, ensuring they were all square of course.
A spot of luncheon and a cuppa left me ready to carry on.
The legs shoulder braces were filed to shape - a small square out off a corner, and then more glueing. This was a tricky bit, as trying to keep them square involved masking tape for the first time. It wasn't to stop me singing along to the radio as the neighbours may have wished but to hold the braces square while the glue dried in the lovley damp, cold winter air of the garage!!!
 |
| Weights to hold the position |
 |
| Must clean the floor soon!!! |
I reckon another update before the weeks out though!
Wednesday, 9 November 2011
Redesigned Shoulder plates - Thanks
The frame was all together and looking good when Dave Everett (who's plans I'm using) decided to update the plans on R2 builders club site. He has made the shoulder plates on the frame with slots to enable R2 to change from 3 legged to 2 legged - albeight manually at the moment.
With this news it was with heavy heart that I had to think whether it was possible to modify the existing in-situ or try and get tehm out and make new ones. I decided on the latter and with knife in hand first one side then the other came out.
The next problem was how to print out just these shoulder plates when they are on the same plan as a body ring!!! A bit of playing about on the computer and printer settings enabled a 'current view' print to work. YEE!!HAA!!
A spray of the repositionable glue on to the styrene and a few slashes with the knife and both shoulder plates and support plates cut and drilled.
While I decide whether to make another top ring with a support for the slip rings, I thought it would be nice to start on the legs. The legs will probably have to be re-made or modified in my quest to make R2 change stance on its own - (unless Dave adds the modifications soon)
The legs inners are made from 3mm styrene and so the plans were stuck on and cut out quite easily actually. This must be sign that I'm getting better or its an easy part to cut out - probably the latter. It was then time to go indoors and spend some time with the wife (she who holds the budget must be kept sweet. LOL). Hopefully on Saturday before working on nights I'll be able to cut out the 4mm square on 8 small pieces of the legs and drill the holes for the electrics, maybe even get the other leg cut out.
I may even see if Skye wants to spend half hour in the garage on Saturday to hinder/help.
With this news it was with heavy heart that I had to think whether it was possible to modify the existing in-situ or try and get tehm out and make new ones. I decided on the latter and with knife in hand first one side then the other came out.
 |
| Shoulders removed. |
The next problem was how to print out just these shoulder plates when they are on the same plan as a body ring!!! A bit of playing about on the computer and printer settings enabled a 'current view' print to work. YEE!!HAA!!
A spray of the repositionable glue on to the styrene and a few slashes with the knife and both shoulder plates and support plates cut and drilled.
 |
| That was easy - just-!! |
While I decide whether to make another top ring with a support for the slip rings, I thought it would be nice to start on the legs. The legs will probably have to be re-made or modified in my quest to make R2 change stance on its own - (unless Dave adds the modifications soon)
The legs inners are made from 3mm styrene and so the plans were stuck on and cut out quite easily actually. This must be sign that I'm getting better or its an easy part to cut out - probably the latter. It was then time to go indoors and spend some time with the wife (she who holds the budget must be kept sweet. LOL). Hopefully on Saturday before working on nights I'll be able to cut out the 4mm square on 8 small pieces of the legs and drill the holes for the electrics, maybe even get the other leg cut out.
 |
| 1st leg nearly done |
I may even see if Skye wants to spend half hour in the garage on Saturday to hinder/help.
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