Mounting the Ankle… stuff

So, after the ankle wedge was done, it was a simple task to just slap some paint on to it.

I’ve been toying around with ideas on how to mount this, as I really want most of the things on the droid to be removable, in case of service!

Not fixed the ankle wedge per se, but I’ve fixed the ankle cylinder and the ankle half-moon (The half round part underneath the cylinder that the cylinder rests on.

I drilled a hole from inside the cylinder down into the half-moon, and went as deep as I dared (watch your thoughts, Edwardo), glued 2 long M4 screws into the holes with superglue, cut the heads off with my dremel (wear goggles people!) and finally just secured them together with two bolts.

The cylinder itself sits tight on the ankle, by pressure alone, and if I need to, I can simply add some double stick 3M tape underneath the half-moon to really fix them into place.

Just look how nice it all looks when it’s all in place.

I still haven’t decided how to fix the ankle itself though. I may use magnets, I’ve got a shipment of magnets coming in..

Please note that the leg itself is not painted, but the half-moon is painted satin white. No clear coat, though.

By | 2016-12-06T00:01:09+00:00 October 11th, 2012|R2-D2|Comments Off on Mounting the Ankle… stuff

Building an ankle wedge

Something I’ve realized over the past year where I’ve been building my R2, is that I really love scratch building things from styrene.

Styrene is very forgiving, and once you’ve learned how, making things is actually quite easy!

Today’ I set out to build a small silly piece with lots of weird angles and stuff: An ankle Wedge! (Actually I built two of them, but who’s couting… I need 4 in total, so halfway there… unless I cave in and use the two resin ones that I do have laying around…)

Anyway, back on track! The ankle wedge is a small piece that is sitting on the bottom of the legs, holding the Ankle Cylinder.

I’ve previously built my ankle cylinders out of PVC pipe and styrene, and even though they still need a bit of work, they sit good enough on my robot in order to me to make the wedges!

These are the main pieces. A big piece of styrene, with no straight angles. The short edge will be closest to the ankle, and the big end will rest on the cylinder. The sides are made up by small triangular pieces. I’ve cut out larger triangles, measure, then place a piece of extra pipe on top my 1mm styrene piece and cut around it (had to cut a few times to get the proper fit) to get the right curve.

This is really a try/test/try/test again sort of procedure in order to get these to sit snug, but after a few test tries, I did get my triangular piece to sit pretty spot on to the cylinder.

Once the triangular pieces are made (be sure to mark them properly so you know which side is which, what is in, what is out, etc) I chamfered the long edge of the flat styrene piece, to make it look good on the cylinder. Then glue time!

Two pieces of tape to hold the triangles to the large piece of styrene, and then just glue it all down!

Once the glue set, I added another piece in the center, just for stability.

Then time to use my secret instrument to make it fit really well…

No, not THAT kind of instrument. It’s not a plastic didgeridoo!

However, the PVC pipe with a piece of sand paper strapped on to it, makes for a perfect tool to sand the little wedge to remove any irregularities after glueing it all together!

Finally, let’s end this brief tutorial with taking a look at the results!

Nice and smooth! Now I just need to paint them blue and set aside as finished!

Oh yeah.. need to make another two… unless I use them old resin ones.. I kinda like these better, and they fit SO much nicer…

By | 2016-12-06T00:01:09+00:00 October 11th, 2012|R2-D2|Comments Off on Building an ankle wedge

Evening Post

Fourth blog entry in one day! I must be nuts!

(well… I *am* building an R2-D2..)

All of them are dealing with different aspects and different parts of the build!

First off, I fixed two things that was on the R2-2DO list that I had just been to lazy to fix: I added the ridges to the second horseshoe, and covered the second horseshoe shim in aluminium, to get that of the list.

I was then contemplating drilling larger holes for the dome ring, and have the dome ring resting not on screws but on larger knobs. This would make removing and replacing the dome much easier!

I took off the rockler bearing from the droid, and at the same time, I drilled holes for the screws in the rockler on my secondary golden dome!

Rockler was mounted again, this time I made sure it was all level, then on with the work!

I glued on magnets on the inside of the “Kenny-Panel”, and glued on small metal shims to the corners of the panel. I took the old inside from the front panel, cut it slightly to make it fit, and fit it inside the Kenny-Panel for powering the droid on and off.

The panel is right now hanging on magnets alone, but I’m going to hinge it tomorrow, to make sure it does NOT fall off! =)

Speaking of hinging: I did hinge the front large door, currently attached with CA glue, but that works just fine for now. I even added a small magnet lock to the door. At the moment I think it is too strong, but I will find a better option shortly.

I even tested it with the restraining bolt, and it works like a charm!

Originally, the bolt was meant to be higher, but I realized I had to turn the door upside down (looks the same both ways) for a better fit, so I’ll have to live with the mount point for the restraining bolt to be slightly lower than I first had counted on. Maybe this was put on by a particularly short jawa!

I also took out the main battery and the electronics board since I need to reroute most of the spider web that are cables inside the droid. I did purchase a few things to make it neater, I just need to work on the cabling a bit!

I will also need to find a better socket to attach to the electronics board. At the moment, it is all individual cables that are just attached to each other. One big connector would be a lot better!

Won’t be too hard either… At the moment, I think I’ll need like 10 channels connecting to the board…. maybe.

By | 2016-12-06T00:01:20+00:00 September 17th, 2012|R2-D2|Comments Off on Evening Post

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