aluminium

A little bit of paint…

Over the weekend, in addition to flying all over the country and performing, I’ve been busy trying to get as much of my droid painted as possible!

I’ve learned a great deal, a lot of do’s and don’ts, and fallen into a number of pitfalls along the way!

But let’s start from the beginning!

After finally realizing that I would need to paint the droid all myself, and most likely on my balcony, I trodded away to the store, got a cheap, foldable workbench and ordered some paint online!

This will do nicely to ge things off the floor and work comfortably!

Part of the paints used. Also note the breathing mask. Definitely a must when working spray paint, even if you are outside!

I started off by sanding off the body with a 400 grit sand paper to get it nice and smooth. Then time to prime with my grey primer, and set off to dry over night. Next step is to sand the primer down to get it nice and smooth, I noticed a few places where I needed to add a bit of bondo, added that, then sanded off some more.

Once I was happy with the surface job, it was time to bring out the white cans. Not being very experienced in spray painting, Obviously I made a lot of mistakes along the way.

I think one thing was that I wanted the results to be done, so I didn’t spray in thin layers enough. One lesson learned was that if I apply thicker layers than just fine mists, not only can it (and did in some places) cause the paint to run, and you need to wait for that to dry and sand and paint all over again, but thicker layers takes exponentially longer to dry than thin layers!

Once the first layer was put on, the body was put aside to dry and I started working on the doors. Same thing there. Prime first, then dry before applying the white paint.

After the white paint was applied, I put the entire sheet with the doors to the side for drying… Another mistake. I used thin papers as “trays” when painting, which was good in itself, but I forgot to think about things like wind.. which resulted in flapping the paper over on to my freshly painted door, and … well .. this:

*ouch* More work. I needed to strip almost all that paint off, then start over. That takes time!

Day two started with wet sanding the body. I removed a few places where the paint had run, and generally scrubbed that droid nice and smooth, ready for just one more layer…

Once dried, disaster struck!

I added one more layer, but it seems that was a bit premature! I got crinkly paint… the orange peel, or cracking paint or whatever you want to call it!

My guess is that the aint was not dry enough after being outside over night (where it was probably a bit moist), and that caused the paint to crack up and peel.

After the sun had been on the balcony for a while, I’ve sanded off most of it, but I’m keeping it inside for tonight and won’t touch it until tomorrow night (earliest) where I need to do a little bit more of sanding, and finally one thin coat of paint on top of this.

Time for a break, as I had to fly down to Malmö to do a gig on saturday evening!

Coming back, I took a few pictures out the window to the white engine, to get some reference photos of real life weathering..

Fueled with this, I’ve continued my paint job with these additional items:

One of my styrene foot shells has been painted.. as well as

The doors for the body and one of the battery boxes… I need to redo one of the doors though. There is a spot right in the middle of the big one where one of the other doors had been accidentally fel on top of, and chipped the paint.. More sanding and repainting tomorrow.. *yay*

I did also paint my utility arms..

.. did a crappy job of doing one of my booster covers, will most likely redo this one tomorrow as I’m not happy with it at all.

My new and improved LDP also happened to pass by under the can…

.. as well as my center vent holder…

… my octagon ports…

.. and my coin slots and arm boxes!

I had to test fit them, and I must say that it feels good seeing this. My R2 has been the colour of plastic for a long time now, and seeing it with the first coat of white on it, made the whole thing look so much more real! Now, I’ll just wait for the paint to dry properly before I do a little bit more sanding, touching up where it needs be, doing a gentle wet sand with 800 grit and finally adding some clear coat on the body!

I must say that I really like how the blue metallic colour that I’m using is looking when applied directly to the metal! Looks like I’ll be stripping away all paint on my aluminium panels before painting them with the current R2 blue of my choice!

I’ve gotten a lot done this weekend, and more to come! I’ve still got a little bit of styrene work to do on my other battery box, and I need to enlarge the leg hole for my power coupler on the right leg. I’ve got a few other small tweaks and ideas that I’m working on as well, but more on that later on!

Right now, it’s time to sleep! =)

By |2016-12-06T00:01:06+01:00October 14th, 2012|R2-D2|Comments Off on A little bit of paint…

Second side vent

First off:

Woohoo! I can has superglue!

The first side vent is therefor complete!

After trying out the “can opener” method on parts of the first vent, I decided to try this out fully on this second vent.

I drilled a large hole (10mm) in the middle of the parts that should be cut out from the second side vent. Just one hole per cutaway rib.

After that was done, I scored fairly deep with my breakblade knife, inserted my pliers in the big hole in the middle, and started rolling the pieces away, and they rolled off nicely!

Fairly good result after I’ve removed the pieces, too!

Since I didn’t drill in the edges, but merely score the short ends, these broke off nice and easily. Don’t worry about it being a bit crooked, I’ve got a solution for that!

My trusty stel ruler laid on top of the vent, and then bang onto the ruler with my plastic hammer, and that seems to work well.

The last few dents was just taken out with my sander.

Not a bad result, and this was done with a minimum of filing, and the corners came out great!

Now, it’s late at night, and I’ve finished glueing my 2mm aluminum clad styrene strips to the back. It’s left to set over night, and tomorrow I’ll paint and add the backing to this second side vent.

Three down, one to go.

Why was I worried about these aluminium vents to begin with? Once I found a method that I liked, it was really a breeze! =)

 

By |2016-12-06T00:01:10+01:00October 8th, 2012|R2-D2|Comments Off on Second side vent

Side vents: do they work as well?

After my initial attempts (that was quite successful) at making the pocket vents, I set out to do a side vent as well today. Mainly because I like to mix things around a bit and not do too many repetative things after another. This would be similar, but different. The pieces are larger and could therefor be slightly more unstable when cutting..

As usual I’ve started with a printout of the vent, and glued this (with repositionable spray glue) on to a piece of 0.8mm aluminium.

Next step was to mark holes near the corners (no need for precision this time, I’m trying another route) and drill them. I also added a larger hole right near the smaller ones, I’ll explain why in a moment.

Holes drilled, all ready for the next step!

Next step is to score two-three times along the lines on what should get cut out. I made the holes bigger in one end, in order to make room for my pliers to get inside, and try out the “wiggle” thing I made for the pocket vents. In hindsight, the smaller holes at the bottom of the picture above was really not needed. Next time, I’ll do without them!

I also scored the short edges, as best as I could. I took great care to mark where to cut so not get mixed up or my view obscured by my steel ruler.

For each of the lines, I scored a number of times extra, this time with no ruler needed, and then inserted my pair of pliers and started wiggling back and forth, sort of doing a score and snap, but with small increments. I did this on both sides of the piece being cut out, and bent away.

It actually worked quite well. I had scored quite deeply, enough to make the line visible through the aluminum, and bent of small pieces, cut them off with my steel plate scissors, bent of another piece and so forth. Once I got to the other end, the holes function as to create a “stop tab” so I couldn’t bend too much.

after a while, I decided to try another approach, just because I felt it took too much time bending it off in small pieces. I basically used the same method used when opening tin cans!

I bent over a piece, turned the entire piece upside down, grabbed it from the other side and started rolling! This worked even better, and I didn’t need to stop along the way, but could roll off the entire length with only a little extra scoring.

I was a little worried that the edges and the plate would be a little too much manhandled, but after all, I was using quite soft and thin aluminium plate.

The straighter lines was the places where I rolled off the entire length as described, while the more beat up lines is where I started wiggling in small pieces.

This is after I had done one session of straightening the piece out!

Straightening out was actually quite easy. I placed my steel ruler along one of the ribs on top of my cutting mat, and use a rubber mallet and pounted on top of my steel ruler, taking sure not to hit the plate. That made it nice and smooth with quite a little effort.

This is the same piece after filing and sanding the front. Quite a big difference, huh?

The obligatory test fit looks good…

Next up is taking the 2x2mm styrene eEergreen strips, and cutting off strips of aluminum tape to dress them. I found a better version of doing this after a while as well..

The set it into place… and glue..

… and wait for it to set. Rinse and repeat…

By lining up several strips at once on a single piece of tape with a good distance in-between… and rubbing down on the aluminium tape from the other side..

.. and then cutting the tape in between the styrene strips, and folding the tape down, this was a MUCH quicker way to make all the ribs at the same time!

So, placing, glueing and fixating until it sets.. It was all smooth sailing until…

OH NOES! I RAN OUT OF CA GLUE!!!

So, finalizing this part will have to wait a bit until I can get out to the store and buy some of the good stuff again. I tried glueing with a lesser brand that I had at home, but the only thing it really managed to glue together was what it was evidentally made for: MY FINGERS!

So, while waiting for the glue I had to (possibly) set on something else apart from skin, I cut out the back plate..

Paint it in your favourite R2 blue…

Even though I cannot glue this into place at the moment, I can still push it against the back to get an idea what the finished vent will look like:

So, my next set of vents will go a lot faster now that I’ve found better ways to do the ribs and also to cut out the pieces!

By |2016-12-06T00:01:11+01:00October 7th, 2012|R2-D2|Comments Off on Side vents: do they work as well?
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