Monthly Archives: August 2012

Fixing the Horseshoes!

As I mentioned in my previous post, I had things I wasn’t happy with in the horseshoes. The ribs inside the inner circle were not eve, due to some issues when routing.

I decided to fix this, using a totally different approach.

First off, I sanded off the irregularities in the fork “tines” of the horseshoe:

Much better. Next step was to sand down the entire rounded portion of the inner perimeter.. This needed to be sanded down at least 1 mm in total… and still be round.

This took a while, but kept a perfect circle!

Next step was to glue a 0.5 mm thick piece of styrene around the inner circle and the “inserts”, to make them absolutely smooth and flat.

Once the glue had set, I sanded off the edges… looks pretty good so far!

I guess that what really made me want to start on the horseshoes today, was this package that arrived from Ryan H, containing these goodies:

I sanded the cavities for the buttons and hydraulics, made a paper template of the hole in order to center the holes properly, drilled and countersunk and .. well .. I just HAD to try them out immediately!

Once the circular piece and the side pieces were glued in place, I cut off 3mm styrene strips of 0.5mm thick styrene, to glue inside the horseshoe to get the right ridged edge. This time without the anomalies I had previously. I started with the side pieces to act as a guide for the circular pieces. In the picture below, you can also see that I’ve glued in the pieces along the edge in the circular part as well.

Once I had the edges and the leading-in side pieces, I just glued the remaining pieces in. These were all done by freehand, bye eyeballing it, but I really think it turned out great. As long as the glue needs a little while to set properly, there is plenty of time to adjust. Not too bad, eh?

This looks a LOT better than it did before.

Next off, I sanded the bottom pieces to be ridged as well, as I had left this part out when I originally made the horseshoes.

So: Aluminum bits in place, the ridges looks nice. This horseshoe is done. There is however one more thing I need to fix..

The shoulder shim. It had not been sitting exactly where it should be, making the horseshoe sit a few mm higher than the shoulder, plus that it should be aluminum.

I spent a good 20 minutes working back and forth with mounting the shim on and off, and working in small increments with a round file in order to expand the holes to be just right. Next step: Aluminum edges!

I took my aluminum tape that I’ve used to skin my shoulder hubs (Another thing to fix later on: Skin the shoulder hubs with real 0.3mm aluminum for a better look) and cut it in thin stripes and wrapped them around the edge.

Once this was done, I re-attached the shim to the horseshoe, and finally placed it back onto the leg. R2 now has a left leg that looks much better!

Yeah … seeing these pictures really makes me cringe with the foil tape on the shoulder hub. That has GOT to change.

Oh, and the blue color, is not the final one. It is just a temporary color I had in the house, since I needed the booster covers blue for midsummer’s…

So: I’m halfway through fixing up the second horseshoe, hopefully get that done by tomorrow!



By |2016-12-06T00:01:26+01:00August 25th, 2012|R2-D2|Comments Off on Fixing the Horseshoes!

Small changes…

Long time no update!

That doesn’t mean that I’ve been lazy though. Granted, I did have a vacation, and enjoyed it and have been relaxing, but building is back on the agenda.

Lately, I just have not had time to update the blog, so this will sort of add up what I’ve been doing lately!

First off, I received a pair of very nice center vents from BobC, and I’ve since assembled them, which required a bit of filing and glueing, then finally remade my center vent holder and mounted the vents inside the holder, and they are now the center peice in front of the speakers that makes R2 talk!

The blue panel still needs to be painted in the correct color, and I think I need to drill and tap for mounting a scre to make the center vents stay firmly in place, even though they are currently squeezed in, and will not go anywhere!

Since I am closing in fast on the day when I actually need to paint my droid (because there will be nothing left to do on him), I’ve started to take care of some of the little things that have been bothering me, and left for later. Parts of this build has been done while stressing to show the droid off at some event or other, so there are parts that I’m not all happy with, and that I feel needs to be touched upon.

First thing was the big door on the front of the droid. I pushed a little too hard, and the door had a very visible “rib” slightly deforming the door. This was too big to just sand and make good, but the entire door needed to be remade.

Here’s the new door, looks a LOT better!

While being at it, I decided to add a magnet inside the door, to hold up my very nice restraining bolt, that Sigge had made for me! The magnet is more than sufficient to hold the bolt, and it looks quite nice!

While being at it, I also decided to add the back door details, in case I want to open this in the future.

I’m still having issues with how to mount the JAG hinges, especially with the big, long doors, as the frame structure is right next to the door, and leaves no possibility of attaching them to the inner skin. I might have to cut the structure and hinge slightly. We’ll see.

I’ve also removed the long doors from the frame, started cleaning them up, and been looking on how to make them more “finished”. Right now, it’s just a thin layer of styrene with some structural pieces glued in on the back, to keep them curved.I got some plans here as well… =)

On the list of things that needs to be touched upon and/or modified, I’ve got:

  • Horseshoes (irregular “ribbing” on the inside)
  • Shoulder shims (fine tune mounting and add aluminum lining)
  • Battery Boxes (“ribs” shouding through skin. Possible reskinning)
  • Foot Details (Details made in 1mm styrene. They should be 3mm)
  • LDP needs back piece for more solid structure
  • Unpainted Back panel needs to be converted into door. Got something special coming in, thanks to the Hero of the Day: Sigge!

The next bit is so big, that it requires a post of it’s own…


By |2016-12-06T00:01:27+01:00August 25th, 2012|R2-D2|Comments Off on Small changes…
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