Received the resin parts from Wayne, wow these are beautiful. The silver looks great, as expected there is some cleanup work on the parts but overall I’ve very pleased. Wayne also included a set of logic frames, front and back. Izzy has a set of these in regular resin but I’ll use these since they are silver already.
I was so excited I had to try out the shoulder hub in my leg – looks and fits great!
Began working on the main feet and the center foot. These are by far the toughest pieces to assemble because of all the chamfering. Its even more critical because the shells add to the structure of the foot so they need to match up or you’ll need to fill in with scrap pieces. Thankfully styrene and IPS3 makes it easy to ‘patch’ things up when you go nuts with the dremel.
For the chamfering, I tried a ton of ‘tricks’. Turns out the easiest for me was to use the dremel freehand for the first couple passes and then use the file to clean it up.
Sheet of foot pieces
Started on the horseshoes, and again the size difference is causing a slight issue that I’ll need to adjust for, there are 5 pieces stacked together which means there is a 0.035″ difference as seen in this picture. Going to add a 1mm filler so the side pieces and box backs match up with the height of the ring sections.
Slight height difference
Graphical representation of the difference between metric and SAE sheet thicknesses on the horseshoes
1mm filler other side
Scrap filler supports
I think Greg was trying to reinforce my reading the directions. Turned out I had an extra sheet of ring sections. The directions say ‘Continuing adding sections until you run out of inner sections’, fortunately I looked at the picture and instead of stacking all the pieces I had, I saw there are 3 inner and 2 outer ring sections. I had enough pieces for four horseshoes, glad I realized.
Extra horseshoe pieces
UPDATE: I found out later that my horseshoes were not perfectly flat, so they didn’t lay right on the legs. I think the 1mm filler was too much causing the back plate to bow ever so slightly. Another one of those mistakes, but a little sanding fixed it.
Ordered the following resin parts today.
Under Shoulder Details
Wayne uses aluminum particles in his pieces so they look like aluminum, decided to go this route for the silver parts instead of using Rub-n-Buff that Izzy keeps saying is easy to use…….we’ll see.
Resin parts: $267
Working on both main ankles, its a lot of styrene laminated together. These things are beefy for being plastic. One issue that did arise is that the 3mm styrene we have is actually 0.125″ thick (SAE), so there is a 0.007″ difference. You won’t notice this until you laminate several pieces together. The main ankle piece that goes into the foot will be slightly wider. The ankles are 8 pieces laminated together so that 0.007″ becomes 0.05″ inches, if I was doing it again, I’d make one of the MAO pieces 0.08″ (2mm equivalent), then the difference would only be 0.01″.
For the record here is the conversion from Metric to US sheets we used
3mm = 0.125″
2mm = 0.08″
This small gap is another result of the slight difference, but since it gets skinned I’m not going to fill it in.
In keeping with my box method keeping stuff sorted
Back to working on the legs and realized I didn’t read the instructions fully. In my haste I glued all the pieces, including LLE which I wasn’t supposed to glue until after you glue on the top piece. This is a critical step since you need to have access to the cross pieces to glue to the top piece,
To adjust for my error, I decide to add guides to the top piece so that it would fit onto the leg. I used two pieces of scrap styrene to make a jig to ensure the guides were offset from the edge of the legs correctly. The one piece of strap is higher so that I could access the guide edge for gluing.
Jig out of scrap
Here is a picture of the top pieces with the guides installed
Since now I’m reading ahead in the instructions I see that the main ankles screw into the legs with four screws. I thought about installed nuts and washers but decided to follow the instructions but added a piece of 2mm to the inside of the leg so that the bolts had more material to attach too. Again, this may be over-engineering it, but better safe than sorry.
Extra 2mm for ankle bolts
Ready to be glued together. This is where it got tricky since I had glued in the LLE pieces. I ended up gluing the top shoulder section, and then after about two hours I lifted up the top piece on the vertical part and being able to get glue in at each horizontal piece. The guides helped to keep the pieces aligned, but also provided additional bonding surface for the legs. Hope they hold up <fingers crossed>
Tip: Read all the instructions first
Spent two weeks at the beach, and now the family is spending the 4th at my folks so time to work on R2. Izzy and I stopped by Greg’s on 7/3 to work on a few droid things. Again, I’m amazed at how much Greg and Izzy are helping me, Greg is spending countless hours working on the cad files to maximize the pieces he can fit on a sheet – thus minimizing the cost. He is also tweaking some items. My R2 will be the first one built from parts off his CNC setup so I’m the guinea pig but a well watched guinea pig – I could never have done this without both their helps. For all those handcutting the styrene, you have my admiration – this would not have happened if I had to do those cuts.
In looking at the shoulder support plates, again my engineering kicked in and thought that a single piece of 3mm would not be enough, it flexed when I pushed on it and if this was going to support a good part of the load I needed to beef it up. Again, of course I didn’t really read the instructions. The styrene sheet I received had two of the shoulder support plates so I assume one on each side and totally missed that you needed to laminate two 3mm pieces together. I beefed up one of them, then went back and re-read the directions – doh!
Ended up picking up the other set of plates from Greg and had to do some creative cutting to get the second piece of 3mm to attach correctly to the one I beefed up – should actually say butchered. Here is a picture of one of the many mess ups…..but styrene is very forgiving.
Screwed up shoulder plate
What it should look like