tag:blogger.com,1999:blog-6391755000606138142023-11-16T07:08:52.242-05:00Paul's Second R2-D2 BuildHere we go again! This blog documents the build of my second R2-D2. Having learned a lot from building my first R2, this next one should take advantage of the things I learned while building the first!Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comBlogger82125tag:blogger.com,1999:blog-639175500060613814.post-56265644592683098152015-04-10T00:00:00.001-04:002015-04-10T00:00:44.542-04:00Beginning work on the Utility Arm Motorization kit <span style="font-family: Verdana, sans-serif;">This week, I started work on the Utility Arm Motorization Kit, offered by Rotopod on the Astromech forums. </span><div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdh4n3xfKYROBdrH9GQs5YR3Uwd8yLxmn6HjWEkwwzyYaBoKVZQQ-i9GlWd06QZIL5HRWRgzLZ9A4FXFEyTVyEYcWafXcy8a21tGt6wbgN7oKDGgV6c0ohgGR0Mn9XBSdaynBo2iIRi4Y/s1600/2-Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdh4n3xfKYROBdrH9GQs5YR3Uwd8yLxmn6HjWEkwwzyYaBoKVZQQ-i9GlWd06QZIL5HRWRgzLZ9A4FXFEyTVyEYcWafXcy8a21tGt6wbgN7oKDGgV6c0ohgGR0Mn9XBSdaynBo2iIRi4Y/s1600/2-Copy.jpg" height="187" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The kit is very complete and his step by step instructions on the forum are pretty much spot on. I did run across a few stumbles, which I hope this blog with clarify for other builders getting ready to put theirs together!</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The structure that holds the arms is called the "Utility Arm Carrier" and consists of the side pieces and horizontal ones. The arms are held in place in there with a shaft, secured with spacers that sit in shallow holes in the horizontal pieces. </span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">With this kit, those spacers are replaced with pulleys and belts, driven by servo motors. </span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">First the horizontal pieces need to have the holes widened The recess will stay but the hole needs to have a 3/8 inch drill bit widen the hole. The allows for the bearing to fit inside.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglJJGU4pQtGX79w4UfMIkZpdyyk0IeOMHnBl_sLCWgi85w9EteFWKMRukj8jDkevlvjZurkQDAVtCSc8vBY2YlKsImygTrw_V2m03fe8kUfEFgOb8FxP60pMamY8hXxZYnUZ4t0TEIFv8/s1600/IMG_8479.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglJJGU4pQtGX79w4UfMIkZpdyyk0IeOMHnBl_sLCWgi85w9EteFWKMRukj8jDkevlvjZurkQDAVtCSc8vBY2YlKsImygTrw_V2m03fe8kUfEFgOb8FxP60pMamY8hXxZYnUZ4t0TEIFv8/s1600/IMG_8479.jpg" height="300" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho6CznneypoKQPqJ4iZBtFzqtQq969adNlQxGmmpecqjlOhCvK4AMPmFyBJq4DeGerymkGEIqEGAR2ArpTipYX1sqHa5Vn7qQco49K04RT-96QD39PBQUB8E6y_9C_DOU-SSbUx1Rg5Zk/s1600/IMG_8480.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho6CznneypoKQPqJ4iZBtFzqtQq969adNlQxGmmpecqjlOhCvK4AMPmFyBJq4DeGerymkGEIqEGAR2ArpTipYX1sqHa5Vn7qQco49K04RT-96QD39PBQUB8E6y_9C_DOU-SSbUx1Rg5Zk/s1600/IMG_8480.jpg" height="400" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">I used an R2-D2 toy as a reference, so I would recall where the pivot point was for each arm. For example, the top one pivots opposite the bottom. I even labeled the horizontal pieces so I would know which was which. In the picture, I have "Bot Top" and "BB" (Bottom Bottom) to indicate they are for the lower arm. On the left you can see "TT" (Top Top) and TB (Top Bottom) written on the pieces. While not necessary, I did it to help maintain order.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">Now on to the Utility Arms, which I <a href="http://pauls-second-r2-d2.blogspot.com/2015/03/back-at-itutility-arm-clean-up.html" target="_blank">recently cleaned up</a> and beadblast the Dykem off of. </span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">First, a hole has to be drilled, then tapped, so that a set screw can thread in and ensure a tight fit for the pivot shaft. The set screw is 6/32 so the hole will be pretty tiny! With the utility arm being curved, I will have to use the hand drill and vice to drill the hole.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">I use the hole punch tool so that I have a divot to drill into. This prevents the drill tip from wandering. Even more important since the area we are drilling is curved and we need a good, straight hole into the pivot hole.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSwd-PkYPZjA0qrDcVxfCShM1ZKvUvmMM67e9xONW_OeatzQ8hsx43-Z5yjQm63U0Tp3e1klzM0rzRLFgC1qc2KuDSi4vH2xYFN0mhl2bSB6ynq-4RSvWRYZ_HmLS8W0yke649PpcXOgg/s1600/IMG_8406.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSwd-PkYPZjA0qrDcVxfCShM1ZKvUvmMM67e9xONW_OeatzQ8hsx43-Z5yjQm63U0Tp3e1klzM0rzRLFgC1qc2KuDSi4vH2xYFN0mhl2bSB6ynq-4RSvWRYZ_HmLS8W0yke649PpcXOgg/s1600/IMG_8406.JPG" height="320" width="240" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGxop6bTp4iSeWD_1oU-XKGcLYHhnESzZkPsWCrNKqGNrTaIb63Tfl12KgBfnXuLBqmknRoBHjR8O_De2Rv9BeKcP1tMkOzVhj6rdxHjt2REv_DFHyk9Po73At3JMqLAv-1eE6HHG9gC0/s1600/IMG_8407.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGxop6bTp4iSeWD_1oU-XKGcLYHhnESzZkPsWCrNKqGNrTaIb63Tfl12KgBfnXuLBqmknRoBHjR8O_De2Rv9BeKcP1tMkOzVhj6rdxHjt2REv_DFHyk9Po73At3JMqLAv-1eE6HHG9gC0/s1600/IMG_8407.JPG" height="320" width="240" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Now on to the pivot shafts. </span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Mine went on extremely tight, I didn't need to sand them...but I did use the vice so I could lightly tap the shaft into place, making sure the flat side faces where the set screw will be.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjntz0bEMkORrEbG-nbDFrOd_a_IZRlFwv2sYtK0Ur96MTCZZty7A553KT4jL6AzRGk6ncESOgurbOUjPuLF77HvACeKDxKET7flck_KTvFxqLkBrfEdEpxurrBk-J2496fhEcqJ78l0t0/s1600/IMG_8481.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjntz0bEMkORrEbG-nbDFrOd_a_IZRlFwv2sYtK0Ur96MTCZZty7A553KT4jL6AzRGk6ncESOgurbOUjPuLF77HvACeKDxKET7flck_KTvFxqLkBrfEdEpxurrBk-J2496fhEcqJ78l0t0/s1600/IMG_8481.jpg" height="300" width="400" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Once they are in, you need to find an extremely tiny metric allen wrench for the set screws to be screwed into position. </span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Then, on to the pulleys. I put the wrong ones on (as you will see in the next few photos), so be sure you are putting these on....</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinGMETv7HtT4MLu-z1hxC-WAMC5LNzwcBH3NL7XIZ5gGPjobN-wyVuQL5yiK5Q9elbhhngyVySs1teUoltPu55hwIknwa-ibXl1yWIHMkNmtkS3Ii9eDE63GPykhVnNfwM_DW1Iptiyi4/s1600/IMG_8503.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinGMETv7HtT4MLu-z1hxC-WAMC5LNzwcBH3NL7XIZ5gGPjobN-wyVuQL5yiK5Q9elbhhngyVySs1teUoltPu55hwIknwa-ibXl1yWIHMkNmtkS3Ii9eDE63GPykhVnNfwM_DW1Iptiyi4/s1600/IMG_8503.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">These go on the Utility Arms! The other cogs will go to the motor</td></tr>
</tbody></table>
<div>
<span style="font-family: Verdana, sans-serif;">And (again wrong pulley in the picture), you line the set screw to flat side of the pivot shift to secure it. Each pulley has two holes for set screws, I put one in each. I also used a mini vice and a small hammer to center the shaft as needed before tightening the set screws</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg18t9dMWbCiT7-9Di3B-50CY2MW_o7ZeC2paXTgaABzRg8zuBXwaUqQP3XrTN-ZIzZSl3TxNDg0qSMXAOJGlD5UfVy0-vi34CuMrWb2Xl0j1mZpGJJ48VESU7quVFpbit6PKtxmMLNHVw/s1600/IMG_8482.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg18t9dMWbCiT7-9Di3B-50CY2MW_o7ZeC2paXTgaABzRg8zuBXwaUqQP3XrTN-ZIzZSl3TxNDg0qSMXAOJGlD5UfVy0-vi34CuMrWb2Xl0j1mZpGJJ48VESU7quVFpbit6PKtxmMLNHVw/s1600/IMG_8482.jpg" height="320" width="240" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU1nR6_coZ3yRW_GLl_EyEfaboGVwE7FjCYh0tasG6rnrAfhaGyl1GNJLVEpCZEFH-SY7rlVDsbNyEhLRaBxIxqo0-5b8DEr_8MM34yYxLU01iiI_qvhwvCBfDhzsD21sw9zzr8nxEmGE/s1600/IMG_8483.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU1nR6_coZ3yRW_GLl_EyEfaboGVwE7FjCYh0tasG6rnrAfhaGyl1GNJLVEpCZEFH-SY7rlVDsbNyEhLRaBxIxqo0-5b8DEr_8MM34yYxLU01iiI_qvhwvCBfDhzsD21sw9zzr8nxEmGE/s1600/IMG_8483.jpg" height="240" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihHbWMRCTIkflezOMY23RQpmkarO8w5_C0y3mnt-yITBv1E3V-Pf9wSLxFtIz-2NX22YMpZWoIKvsAKAXcb0FOWWMcJxYENe1nUvDW3qyNE_EPnOzE1aS3IrWs46TFptFwjMRod6yy_zA/s1600/IMG_8486.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihHbWMRCTIkflezOMY23RQpmkarO8w5_C0y3mnt-yITBv1E3V-Pf9wSLxFtIz-2NX22YMpZWoIKvsAKAXcb0FOWWMcJxYENe1nUvDW3qyNE_EPnOzE1aS3IrWs46TFptFwjMRod6yy_zA/s1600/IMG_8486.jpg" height="240" width="320" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Now, time to piece together the Utility Arm Carrier while adding some new mounting pieces.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">I found by putting the top and bottom pieces on, then loosely attaching the back plate worked best. You'll find you need to really squeeze the back plate at times to get holes to line up.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ9Vel7ezi0SX8OTE_PXNTxVsUgVbRrp1WRnu3m-aul3tt10v2r6TO2DmmAnEzOZRJWsOQwnsu1Fy1Y_urFKSNXyf0F3fqhpXS1MMSTxeB7pyFhEIF2ONvAUroKfCJCE6QtmZ8ZnzHWy0/s1600/IMG_8495.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ9Vel7ezi0SX8OTE_PXNTxVsUgVbRrp1WRnu3m-aul3tt10v2r6TO2DmmAnEzOZRJWsOQwnsu1Fy1Y_urFKSNXyf0F3fqhpXS1MMSTxeB7pyFhEIF2ONvAUroKfCJCE6QtmZ8ZnzHWy0/s1600/IMG_8495.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Notice the widened hole on the lower left, which, looking at the R2 statue, matches where the pivot piece is<br /></td></tr>
</tbody></table>
<div>
<span style="font-family: Verdana, sans-serif;">Next, the frame mounting brackets go on. As a reference, this picture from Rotopod's instructions reminds you which one is mounted higher than the other.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-HZnSDZg3aoMgEEO_X59IS2IwEMfI4RDnw00A73Fndsadpnr6YmBvtbcJ_i-fuX9940Mv-i6S_hgWWzmMBiOCL_ngLXpGSt5P1z6x1xjAHF4xVA9gOXjwzBwMBNkbZDBfsyu3yQrE6nI/s1600/2014-06-29-17.01.09.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-HZnSDZg3aoMgEEO_X59IS2IwEMfI4RDnw00A73Fndsadpnr6YmBvtbcJ_i-fuX9940Mv-i6S_hgWWzmMBiOCL_ngLXpGSt5P1z6x1xjAHF4xVA9gOXjwzBwMBNkbZDBfsyu3yQrE6nI/s1600/2014-06-29-17.01.09.jpg" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">To attach the mounting brackets, you wind up doing some delicate swapping around of the machine screws. What was holding a piece on gets removed, then put back on with the mounting bracket.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHxpb-FTUTZ5Cq_DMfMdM4_TrQL-4Qcrbnern65H5n0ElhIXX9cJiVbsRAYkgY6DRKKB_m-4_jqFHqFVOArhsi7Bxt144EM4BHHkA8CtmJrGEo9ATSLRX6W9G8zMernfWDJOdj4RkgROY/s1600/IMG_8496.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHxpb-FTUTZ5Cq_DMfMdM4_TrQL-4Qcrbnern65H5n0ElhIXX9cJiVbsRAYkgY6DRKKB_m-4_jqFHqFVOArhsi7Bxt144EM4BHHkA8CtmJrGEo9ATSLRX6W9G8zMernfWDJOdj4RkgROY/s1600/IMG_8496.jpg" height="300" width="400" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Now its time to see how well the utility arms fit. Shims are included, as needed...and many had to sand theirs down considerably. With them in, I couldn't screw the horizontal piece back in. Too thick, need to sand them down thinner.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibGN3FQ_pJNrAM9Y_QbeCxYg-OCdKTHnQn8WQQD5MGCGlsYiOB0cZDOk9znCCZxa-TUps3dHr3ip7Z5mACJKxL7wolpyE9Isrn-vxBq-7rrQUbu-9PRpqyw-jOJ2Cv1uesTWbwrW49XMw/s1600/IMG_8502.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibGN3FQ_pJNrAM9Y_QbeCxYg-OCdKTHnQn8WQQD5MGCGlsYiOB0cZDOk9znCCZxa-TUps3dHr3ip7Z5mACJKxL7wolpyE9Isrn-vxBq-7rrQUbu-9PRpqyw-jOJ2Cv1uesTWbwrW49XMw/s1600/IMG_8502.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Note on the right, the holes are showing, meaning the spacers are too thick. Thinner spacers will move the horizontal support up a bit, allowing it to be bolted back together<br /><div style="text-align: left;">
<br /></div>
<div style="text-align: left;">
<br /></div>
<div style="text-align: left;">
<span style="font-family: Verdana, sans-serif; font-size: small;">I sanded and sanded...but was still not working out.</span></div>
<div style="text-align: left;">
<span style="font-family: Verdana, sans-serif; font-size: small;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwmFv1Uhepe0EQGjuiMOfM6h7cTSH7sUZ5IEJkoS_GyUVvQ-eNzQq2KLjU_69Z8jvEIw7j6h-sFFojQOEzax6rl9zKSGLgz9iiFQwhQf3F7Lw80_5v6Ett5ImX0bs6DO5-9y7rrwE7Flw/s1600/IMG_8506.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwmFv1Uhepe0EQGjuiMOfM6h7cTSH7sUZ5IEJkoS_GyUVvQ-eNzQq2KLjU_69Z8jvEIw7j6h-sFFojQOEzax6rl9zKSGLgz9iiFQwhQf3F7Lw80_5v6Ett5ImX0bs6DO5-9y7rrwE7Flw/s1600/IMG_8506.jpg" height="240" width="320" /></a></div>
<div style="text-align: left;">
<span style="font-family: Verdana, sans-serif; font-size: small;"><br /></span></div>
</td></tr>
</tbody></table>
<div>
<span style="font-family: Verdana, sans-serif;">...so I decided to improvise and drill 0.25 inch holes in some plastic packaging, cut it out into the shape of the shims and install.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDt5S-IbOBk9qYWtZzhbe5MOaC06gxZwo0Wv0ZHp0RFdrgxD2YmQwy23vH4zCvIatfZTqA8v0pvr5N-nnIfV69r6Q33coMokXwZSgJ2fQaQEzjqaoNOsPPZ1iJmPEDmKlkTkuyHvaSrEk/s1600/IMG_8507.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDt5S-IbOBk9qYWtZzhbe5MOaC06gxZwo0Wv0ZHp0RFdrgxD2YmQwy23vH4zCvIatfZTqA8v0pvr5N-nnIfV69r6Q33coMokXwZSgJ2fQaQEzjqaoNOsPPZ1iJmPEDmKlkTkuyHvaSrEk/s1600/IMG_8507.jpg" height="320" width="240" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">...and everything fits. I am able to screw everything back together and the arms move freely with so friction/rubbing. Furthermore, the arms are straight and not sagging.</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSYNB1VwBlYfJgl9LvHYkLn2XcIJICmKJkVv554lfKFXfhVrRglx4h4dLe00Ya8Yrq3Dq71tou1Db7oYTbXhy2bwjTd-2gaT8iZ1WYM4H54_nvyZxDah9EApoz7GQQFjlE-EfsY0_n9I0/s1600/IMG_8508.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSYNB1VwBlYfJgl9LvHYkLn2XcIJICmKJkVv554lfKFXfhVrRglx4h4dLe00Ya8Yrq3Dq71tou1Db7oYTbXhy2bwjTd-2gaT8iZ1WYM4H54_nvyZxDah9EApoz7GQQFjlE-EfsY0_n9I0/s1600/IMG_8508.jpg" height="240" width="320" /></a></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;">Right now, I am awaiting the arrival of the servo motors for the next few steps...more in a day or two!</span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div>
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-12607957131508330442015-04-01T22:20:00.002-04:002015-04-01T22:20:18.654-04:00New Foot drives!<span style="font-family: Verdana, sans-serif;">Over the last few nights, I have been assembling the NEW foot drives for R2.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;"><a href="http://pauls-second-r2-d2.blogspot.com/2011/03/jag-foot-drives-have-arrived.html" target="_blank">Back in 2011</a>, I had purchased a JAG foot drive for this droid, identical to what is in my first droid. That drive system takes the output from the motor, gears it down via a belt drive to the wheel. The housing fits perfectly in the foot shell and the drive system uses a motor that is extremely easy to acquire. Where this is using one drive wheel, a caster wheel is used to keep R2 level.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYDdLu80SMTIZCuC_fysgDdTd2cC4Vih_pr4Zoh2sj_Ej91-iyrOeMmf7KqIih-g7Z7qFajWUCp1RoIWbWd0CbOIzEbPi5SkSheDpCmKFa9mgf7FIuNSypj0MvggOI6QrcK4nEDhwSp1Y/s320/005.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYDdLu80SMTIZCuC_fysgDdTd2cC4Vih_pr4Zoh2sj_Ej91-iyrOeMmf7KqIih-g7Z7qFajWUCp1RoIWbWd0CbOIzEbPi5SkSheDpCmKFa9mgf7FIuNSypj0MvggOI6QrcK4nEDhwSp1Y/s320/005.JPG" height="240" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Original JAG Foot drives<br /></td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">A couple of years ago, a fellow R2 Builder was looking for some foot drives to complete their R2 build. Since my build had quite a few years to go, I sold these to him and figured I could purchase a replacement in the future.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Fast forward to 2013 and Jerry Greene has improved his design, now featuring "four wheel drive". Meaning, the 2 wheels in each foot will be powered, no more dragging a caster wheel inside. Those have been problematic for me, sometimes causing R2 to get stuck trying to cross uneven surfaces.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">When Jerry first posted pictures of the prototype, many of us were interested!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKhUAo9fJwL5qrWuZWHKvx4Lf88RQkhm6jG6sksCJOkBxwpqT44cvxDOYF6omBV89Dvdaz5MAlLMip15SE3OZoCjvJ4XVVLcov6vgCvgOsoqfbhx2Xvk3lhpgrtgCHvhVwyCjhR5yIOow/s1600/IMG_5210.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKhUAo9fJwL5qrWuZWHKvx4Lf88RQkhm6jG6sksCJOkBxwpqT44cvxDOYF6omBV89Dvdaz5MAlLMip15SE3OZoCjvJ4XVVLcov6vgCvgOsoqfbhx2Xvk3lhpgrtgCHvhVwyCjhR5yIOow/s1600/IMG_5210.JPG" height="300" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The benefits of this drive kit over the previous one is simple: More power! Better ability to cross uneven surfaces, since both wheels are powered and no caster wheel causing issues binding or not being level.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">And...it makes having R2 in 2-leg mode a bit easier. R2 will be level, standing on 4 identical tires!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The kit has a fair amount of parts but between the exploded-view drawing Jerry includes and pictures of a step-by-step assembly, it goes together fairly smoothly.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">There certainly are some tight spots to deal with, such as maneuvering a wrench around four closely spaced hex heads!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg7duvQuGbaomz150BA_jRY7iwRFUKrLPH62A8wcl-a-v_Bu05WaP1x2e_5bUiVhK3MaE3kyR2ZzxHkbvU6yMwsh8oUH8hrO1xuPOZ7SO0ZBBY_Re7-r5J5SlqVkl6MF_ncb8Vj-1D4TE/s1600/IMG_8348.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg7duvQuGbaomz150BA_jRY7iwRFUKrLPH62A8wcl-a-v_Bu05WaP1x2e_5bUiVhK3MaE3kyR2ZzxHkbvU6yMwsh8oUH8hrO1xuPOZ7SO0ZBBY_Re7-r5J5SlqVkl6MF_ncb8Vj-1D4TE/s1600/IMG_8348.JPG" height="400" width="300" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Some tight spots for tools!</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"> With the help of my loyal, 15-year old cat, Mokey, we slowly assembled the foot drives. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHbUOK-_YhV6ypink6ykEj1z44zvhI2adsm31kXkQTwhgzOKse5IXlvnPAHEdQfifb4KFelJy8byrWFHHkpJTfegi-inNSKS8VR4UnnZEEK_TVJLt5BXPMH1MOp2SV3PLMZLlkx1RRmjw/s1600/IMG_8340.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHbUOK-_YhV6ypink6ykEj1z44zvhI2adsm31kXkQTwhgzOKse5IXlvnPAHEdQfifb4KFelJy8byrWFHHkpJTfegi-inNSKS8VR4UnnZEEK_TVJLt5BXPMH1MOp2SV3PLMZLlkx1RRmjw/s1600/IMG_8340.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Laptop showing the assembly photos while Mokey supervises</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">This is all a test fit for the most part, since some dis-assembly will be required later. Later, I will need to drill holes in the foot shells to mount the assembly into it.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">On to the assembly...</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaaKrT9KcvuTHOtlqIzvUhbRwfYnH3pUygyZsp5j1NjrBmZVmnMK9Bp3hp_TspxtNyLHq0972gHoe-P3ceG0XZimMxIv9IX4v13nKcZe873LIaPm0AWrH1UvOzrNF4EBDEsvM1yFa1SXo/s1600/IMG_8423.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaaKrT9KcvuTHOtlqIzvUhbRwfYnH3pUygyZsp5j1NjrBmZVmnMK9Bp3hp_TspxtNyLHq0972gHoe-P3ceG0XZimMxIv9IX4v13nKcZe873LIaPm0AWrH1UvOzrNF4EBDEsvM1yFa1SXo/s1600/IMG_8423.jpg" height="300" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf67Rz_yn-zhQyAyZji8DN5dR50edsn0aZ2aX5eKYT7qubytys-E8TlEE2bdME000JXnNNrqMfXIvvwCIBO0YfojUV03g2ySKE8DsOnQwPzNqS-GVhIYEVhPeiIk1Zu3S2Ke4kU7uePWo/s1600/IMG_8434.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf67Rz_yn-zhQyAyZji8DN5dR50edsn0aZ2aX5eKYT7qubytys-E8TlEE2bdME000JXnNNrqMfXIvvwCIBO0YfojUV03g2ySKE8DsOnQwPzNqS-GVhIYEVhPeiIk1Zu3S2Ke4kU7uePWo/s1600/IMG_8434.jpg" height="400" width="400" /></a></div>
<br />
<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEe9FzH29F3CzThSdx49G7_dBN8B9LHsvUue35KoROramz90lsZQdyRZ0vOPWBlM2zllw8t7j-3c8eJX4DjuZzoXCtqs_2H0aU3wxiogRycpMvTXW7_21ObxpaObpOyMd9_72SSyBf5es/s1600/IMG_8435.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEe9FzH29F3CzThSdx49G7_dBN8B9LHsvUue35KoROramz90lsZQdyRZ0vOPWBlM2zllw8t7j-3c8eJX4DjuZzoXCtqs_2H0aU3wxiogRycpMvTXW7_21ObxpaObpOyMd9_72SSyBf5es/s1600/IMG_8435.jpg" height="400" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The belt pulley mount was an interesting challenge. The housing makes getting the allen wrench in there a bit tricky! Then, once you have the pulley mounted and the belt tight, you can't help but notice how tight the clearance is. While hard to see in this photo, the belt comes close to the adjustable wheel mount (shiny piece). It looks good, I don't think it will rub.</span></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV7seiDVuaZpShgz2yg1GlFdMnCsBfCjHVcQEgSBbWYKIWx6Ewrm8ympdyKAgBTIiVDUuRLYEA0DHUJtupwiDB8dS_ZeIWtqgXky_6Ae4KC9eM-zN2CVgXgoXgRrMEteKitMboi7lNazM/s1600/IMG_8454.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV7seiDVuaZpShgz2yg1GlFdMnCsBfCjHVcQEgSBbWYKIWx6Ewrm8ympdyKAgBTIiVDUuRLYEA0DHUJtupwiDB8dS_ZeIWtqgXky_6Ae4KC9eM-zN2CVgXgoXgRrMEteKitMboi7lNazM/s1600/IMG_8454.jpg" height="400" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The finished drive kits!</span></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqe74Z1atW9TMi42vUgu7UxYPCVR3e1tIRsn5cVV3PueEKYygdiWMip_p6K7JnKqHj46E5OJMDLv9mVabR_q9zZ8i0r329SYF8qYY_HRwYX0-W2Y1rBPyZMuIs56UwFsd-reEHCO-lJyE/s1600/IMG_8460.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqe74Z1atW9TMi42vUgu7UxYPCVR3e1tIRsn5cVV3PueEKYygdiWMip_p6K7JnKqHj46E5OJMDLv9mVabR_q9zZ8i0r329SYF8qYY_HRwYX0-W2Y1rBPyZMuIs56UwFsd-reEHCO-lJyE/s1600/IMG_8460.jpg" height="300" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">In a few weeks I hope to have the motors on hand to complete the fit test. I want to make sure the belt will work out alright.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Once that is completed, then the next step will be the installation into the foot shell!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Thanks for reading....progress continues!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-87263377734231310852015-03-20T21:27:00.001-04:002015-03-20T21:27:26.156-04:00Back at it...utility arm clean up!<span style="font-family: Verdana, sans-serif;">It has been several months since I last posted any blog updates on my R2 build! </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">My last update was in July and since then, I lost my job, was unemployed for a few weeks, picked up a part-time job, took all the hours they would give me, and then found a new full-time job! </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">During those weeks of unemployment and under-employment, I just didn't have the motivation to work on my droid. Funds were tight, so the last thing I wanted to do was work on the droid, then discover I needed parts I couldn't afford. Why deepen the depression, right? </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Now, I am working full-time and I also kept the part-time job as well. I'm making ends meet and trying to replenish the savings account while also having a modest droid building budget!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">That said...here's what I have been up to...</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Last time, I was back tracking on the Dykem metal dye, using acetone to clean it off the utility arms. One problem was some areas of the arms still had the dye. I really wanted to remove more than the acetone did. The cut outs that reduce weight were still quite blue inside. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj-8EUgCKMzYhR2suOZARgsEiIGc4VXxqrGoMsT2u9nR8P0iPsjkeRtqJasY4IENfQUIHCmiwYBk4NlzLO8zRIOqwahwc1y2kCvn_0iIMu9mwkzlj8lcRhoiUr5YNwNnv9-NXQktO_UwM/s1600/IMG_8375.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj-8EUgCKMzYhR2suOZARgsEiIGc4VXxqrGoMsT2u9nR8P0iPsjkeRtqJasY4IENfQUIHCmiwYBk4NlzLO8zRIOqwahwc1y2kCvn_0iIMu9mwkzlj8lcRhoiUr5YNwNnv9-NXQktO_UwM/s1600/IMG_8375.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Utility Arms have cut outs milled to lighten them.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPE4wAN5GneaV8lvwuDsUT32pw5KK8MuOIK0sTB8zbfarklmLwENR7oofa8CUqh8mz_xBOwKxLht1Ju6vVf3BOwKt_L4xbsM0k4SAoazbmsLVExryU1Xm-0VIkLywvJdF5FUpC1QoinNc/s1600/IMG_8377.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPE4wAN5GneaV8lvwuDsUT32pw5KK8MuOIK0sTB8zbfarklmLwENR7oofa8CUqh8mz_xBOwKxLht1Ju6vVf3BOwKt_L4xbsM0k4SAoazbmsLVExryU1Xm-0VIkLywvJdF5FUpC1QoinNc/s1600/IMG_8377.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Leftover metal dye that the acetone bath didn't melt away</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The arms are very shiny and I wanted to bead blast them anyways. This would help remove more of the dye and roughen the surface up some. That would be great for when it is time to prime and paint them. (With what paint formula remains to be decided!)</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">My pal, Fred, picked up an inexpensive bead blaster from Harbor Freight a year ago. And as you would expect from such a bargain price, it was pretty finicky to work with. Using 80 grit glass beads, it would work well for a few minutes, clog (spit only air), require some gentle prodding and then resume work for a couple minutes. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPh3EcIsalwWbTbeG9xfz84-YsN75cqsUPKkVvTG0O94jFHS7sttIXIw3PZ9J0EUVzhjdc8ab3iTzO0M630L4LBUSksdjbzMLLwYUrDdFSuKVH8uU1CoanqcrvgIhyYNKl-EXuIl5vKlw/s1600/IMG_8379.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPh3EcIsalwWbTbeG9xfz84-YsN75cqsUPKkVvTG0O94jFHS7sttIXIw3PZ9J0EUVzhjdc8ab3iTzO0M630L4LBUSksdjbzMLLwYUrDdFSuKVH8uU1CoanqcrvgIhyYNKl-EXuIl5vKlw/s1600/IMG_8379.jpg" height="300" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Harbor Freight bead blaster and Utility Arm</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">After 45 minutes of work, I was satisfied I had done as much as I could.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_NtqEpRUAKu9-b3m4m9Yb-MVwDwSkTtlsnGTF92RY_C_BJgHtPbnuwBOUzylgg2l4UbGN6WBtjjyN9_tXGQmeBNk1Kif7FUQpY6nawX5UF76pQiBQf4Hf8CXHxZ6CggWtSev0A0Y_CiM/s1600/IMG_8380.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_NtqEpRUAKu9-b3m4m9Yb-MVwDwSkTtlsnGTF92RY_C_BJgHtPbnuwBOUzylgg2l4UbGN6WBtjjyN9_tXGQmeBNk1Kif7FUQpY6nawX5UF76pQiBQf4Hf8CXHxZ6CggWtSev0A0Y_CiM/s1600/IMG_8380.jpg" height="300" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiE546nU9GashZ9LicY4e7BR65Mj1Q8_NpruT002ztfYguMx8N0JOkpOlrHTMpfk75qZx7VZ2pXy5dOzlvFnL3HVg3ZMUwobTcUOB-zwUyb3jS3gDH3lNYiLVRApbUrehzAM6WncoSSqfg/s1600/IMG_8381.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiE546nU9GashZ9LicY4e7BR65Mj1Q8_NpruT002ztfYguMx8N0JOkpOlrHTMpfk75qZx7VZ2pXy5dOzlvFnL3HVg3ZMUwobTcUOB-zwUyb3jS3gDH3lNYiLVRApbUrehzAM6WncoSSqfg/s1600/IMG_8381.jpg" height="300" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Next time, I will start assembling the Utility Arm mechanization kit that a fellow R2 Builder developed last year. It looks very cleverly designed and I am anxious to start on it!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-30345871491292958032014-07-30T22:31:00.000-04:002014-07-30T22:31:04.105-04:00Time to re-think R2-D2 Blue!<span style="font-family: Verdana, sans-serif;">Back in 2012, many of us R2 Builders thought we had found the perfect blue! We stumbled onto Dykem, a metal dye that was used on the original R2-D2s in STAR WARS A New Hope. It appears the crew were doing a fair amount of touch ups during filming since the Dykem blue goes to all purple after a while, so to stay blue, frequent touch ups and re-do's are needed.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">We thought we had it nailed down to a decent formula. Polish the aluminum pieces (plastic pieces need a shiny silver base coat), apply the Dykem, apply a coat of DupliColor Metalcast Blue Anodized and a few coats of a UV clear coat. However getting Dykem to go on well was a challenge with my airbrush. Then, there was how those purplish-blue pieces look a year later. Based on pictures other builders posted, it was an eventual failure. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">I painted several of the pieces in my <a href="http://pauls-second-r2-d2.blogspot.com/2012/10/working-on-new-r2-d2-blue.html" target="_blank">2012 post</a>. Any some of the pieces came out really good, despite a very laborious process. However, close to two years later, the color has changed. Now that I have a new 300 mm dome ready to be un-boxed, prepped and painted, its very important all the "blue paint" matches!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Currently I am testing some formulas/recipes that other builders have used and are pleased with. Some are rattle-can formulas, as I used on the first R2. The blue I have on the first R2-D2 is what we call "<a href="http://paulsr2d2.blogspot.com/2008/05/metallic-purple-has-arrived.html" target="_blank">Krider Blue</a>", but the Rustoleum Metallic Purple has been discontinued. I'll post pictures of the tests later on!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">That said, today was all about removing the paint. I figured out a low tech way to do this...used two paint roller trays and an old paint brush. I filled one with water and the other I filled with enough acetone to work the part around in. (SAFETY REMINDER - I did this outdoors with plenty of ventilation, eye protection and gloves!)</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOUL5hMEWV01odH9Hyp1wbwrLIITjEDobkEUCj9kl6VMG_90T3KAUPmaLjPPhaEPEkLblIvFvdmA-3LzcMG8aNmOFHqXu2XXI_TloVfTdBZqeu_kpLDEPAn3EDl7Pxf6V93TNZAqSZe3Y/s1600/IMG_7384.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOUL5hMEWV01odH9Hyp1wbwrLIITjEDobkEUCj9kl6VMG_90T3KAUPmaLjPPhaEPEkLblIvFvdmA-3LzcMG8aNmOFHqXu2XXI_TloVfTdBZqeu_kpLDEPAn3EDl7Pxf6V93TNZAqSZe3Y/s1600/IMG_7384.jpg" height="298" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">In went the utility arms and using the paint brush, I just kept slowly applying acetone to the part. The paint and dye quickly started to peel off the part. So much so that it was clogging the brush bristles and the acetone was full of chunks of paint. After the part was pretty much free of paint, into the water it went.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJaKqat3bnqiwd9_boYJ7aBtqVYDRNWi6qZ-gQG6c0tuI6_bUYPxYLDjBgYpzwQ8Y6d0v9OqFhwzhg6CX3vDNhHyOhzI83esQh6AJg9dX5Fx3zGk93duemmHElv_rcr65dASc3xeaoNZM/s1600/IMG_7385.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJaKqat3bnqiwd9_boYJ7aBtqVYDRNWi6qZ-gQG6c0tuI6_bUYPxYLDjBgYpzwQ8Y6d0v9OqFhwzhg6CX3vDNhHyOhzI83esQh6AJg9dX5Fx3zGk93duemmHElv_rcr65dASc3xeaoNZM/s1600/IMG_7385.jpg" height="298" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTiEkl17uL68t8eMBpim5FJZMpYOJakDtQMoRdUzR1iyBDpFRiRe62MO6eXKRZ6MObPn-KWrse-gWr9QSSPvuJ_lyvv3wToWvo3KCbZAYpRrVX2JFsfIJlmpC4Pw4Kl0oSs5zCQPLi2XU/s1600/IMG_7386.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTiEkl17uL68t8eMBpim5FJZMpYOJakDtQMoRdUzR1iyBDpFRiRe62MO6eXKRZ6MObPn-KWrse-gWr9QSSPvuJ_lyvv3wToWvo3KCbZAYpRrVX2JFsfIJlmpC4Pw4Kl0oSs5zCQPLi2XU/s1600/IMG_7386.jpg" height="298" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<span style="font-family: Verdana, sans-serif;">Now my method is hardly the best, in hindsight. I wound up using a cloth with acetone on it it to wipe off those stubborn specks. The resin eye is going to take some more work since the silver base-coat will require some light sanding to completely remove all the paint and primer.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The aluminum arms have cut outs to make them lighter, which also means you can still see paint in side those holes. Those will require a bit more labor to be completely free of paint and dye!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQPIJ7aCyDgcxJzS303OQjD_HLQI1X_xUEFNT_K8h4WjFZ5ZeAWUfmFccPTlkARrp0rirPivZy844wDto6vviuc0rn3h6gD3swh-bZM7vvBtBJhZyAU7y3lkADiXNq7tXSiXE8ojUQovY/s1600/photo.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQPIJ7aCyDgcxJzS303OQjD_HLQI1X_xUEFNT_K8h4WjFZ5ZeAWUfmFccPTlkARrp0rirPivZy844wDto6vviuc0rn3h6gD3swh-bZM7vvBtBJhZyAU7y3lkADiXNq7tXSiXE8ojUQovY/s1600/photo.jpg" height="298" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<span style="font-family: Verdana, sans-serif;">Many more parts to remove paint from!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Next up will be modifying the aluminum utility arms so they can travel in and out of the body skins. More soon....</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtptV-b8Wet8wzqp61Gu6rE7bAlMffIyhPZLoXEgWfZ1z9IC9KROXSjDZXpW7jWG-D8jlyO5CIyX101r2qyqPLjl5BeBX3613H8xEEVNhvFQZRIkuLRSPyCTvOrNSCgv1ieVdpg0WzcvQ/s1600/Capture.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtptV-b8Wet8wzqp61Gu6rE7bAlMffIyhPZLoXEgWfZ1z9IC9KROXSjDZXpW7jWG-D8jlyO5CIyX101r2qyqPLjl5BeBX3613H8xEEVNhvFQZRIkuLRSPyCTvOrNSCgv1ieVdpg0WzcvQ/s1600/Capture.JPG" height="215" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-42195058816240616112014-02-19T20:25:00.004-05:002014-02-19T20:25:58.165-05:00Lifter mechanism motor work<span style="font-family: Verdana, sans-serif;">Work continues on the lifter mechanism!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The challenge this time is the motor shaft to gear connection.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The original design uses metric pieces, which are available in Europe but not locally!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The design uses a Module 1.0 rack with the 12 tooth gear. You don't appreciate how tight those tolerances are until you order a few "I think this will work" pieces from eBay and wind up with a stack of parts that won't work!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Add to this a 12 volt, 300 RPM motor with a metric shaft diameter of 6 mm.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">So, we jump into our arithmetic (that's "math" for you kids!) and determine that 6 mm is 0.23622 inches. This number comes in handy in a moment.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The solution to not being able to purchase the Module 1.0 brand rack and gear was to buy something similar from McMaster Carr. I purchased the 20 degree steel rack and two 15 tooth gears to go with it. I shipped the steel rack to a local machine shop to cut them down to specified lengths and have the holes and grooves cut. Once back, those were attached to the brackets.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWZ9ApoRPDEbkoI3ppRWh6-qDLB5Kt6VVoRjVVYPzvPXjXQL317cuXEfSymyb6dba5IS6r7O94SjsjFj8qqlgvBIRuJX3_zMPkR2wqhwJ-NSTS5NjD1xf18Obp4m0lHsiVX5SkYkDr4u4/s1600/IMG_6015.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWZ9ApoRPDEbkoI3ppRWh6-qDLB5Kt6VVoRjVVYPzvPXjXQL317cuXEfSymyb6dba5IS6r7O94SjsjFj8qqlgvBIRuJX3_zMPkR2wqhwJ-NSTS5NjD1xf18Obp4m0lHsiVX5SkYkDr4u4/s1600/IMG_6015.jpg" height="320" width="238" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY2ntz0kj_zokchu72JZhJ8UfQY_mo30QwfBym3NF3XK6kMM6Jf8HW-jy3ZAQCN1zpK0O1Yj-a0E2rU8JR-yXnvfAd-ObQdZr4i0GWuYmIdylhb-H_pN0FuRTGqbFd7246CJRJ2p3fGho/s1600/IMG_6016.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY2ntz0kj_zokchu72JZhJ8UfQY_mo30QwfBym3NF3XK6kMM6Jf8HW-jy3ZAQCN1zpK0O1Yj-a0E2rU8JR-yXnvfAd-ObQdZr4i0GWuYmIdylhb-H_pN0FuRTGqbFd7246CJRJ2p3fGho/s1600/IMG_6016.jpg" height="320" width="238" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The gear bore has a 3/8" diameter and the motor shaft is 0.23" I was able to find a bearing that has the outside diameter of 3/8" and an inside diameter of 1/4 inch. Which is really close, 0.25" versus 0.23"</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMEIYBd5dSccZVVQ0fdnudWmRAzi8yf2-SAqGg2516UoDlGdxspJl5J7MHnI8DumeCEG-9iK9bhGL-6ipyBX0hwfLse470NovfeKK2uF6RknBuZIo_qP03TS80CG_-R5bnDrpytsK7_1s/s1600/IMG_6253.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMEIYBd5dSccZVVQ0fdnudWmRAzi8yf2-SAqGg2516UoDlGdxspJl5J7MHnI8DumeCEG-9iK9bhGL-6ipyBX0hwfLse470NovfeKK2uF6RknBuZIo_qP03TS80CG_-R5bnDrpytsK7_1s/s1600/IMG_6253.jpg" height="239" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKHywptdA8HvNphjjBnb02l-leb9-2IbTU2QwRiQ0klnAAp6TY4zQqCoGQo3V8k4AOKjfOILLEKeSf_zxjxdZ14ekG2qnMCtGxGX0dFcs7RxjQv2QdSPoHchVHzl-XRe0PVAievJrv60k/s1600/IMG_6254.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKHywptdA8HvNphjjBnb02l-leb9-2IbTU2QwRiQ0klnAAp6TY4zQqCoGQo3V8k4AOKjfOILLEKeSf_zxjxdZ14ekG2qnMCtGxGX0dFcs7RxjQv2QdSPoHchVHzl-XRe0PVAievJrv60k/s1600/IMG_6254.jpg" height="239" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">My approach is this...drill and tap a 10-24 thread hole into the gear, drill a slightly large hole in the bushing, then use a set screw to screw the set screw into the flat side of the motor shaft. That should help tighten up some of the 0.02" difference</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirlis-mkTqEfZdv5OwE7yZC8H6Ms4TqnGrb7FMyat92i5CbFhxKnZOFzeaM2-3feik8rbsRAlHcrC4Zy4Tx5-aDTns8vbpyFhljFPMEr9hgAS7KigXnEuyh-rZkjA3A2c6HPbqOQsPkk8/s1600/IMG_6255.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirlis-mkTqEfZdv5OwE7yZC8H6Ms4TqnGrb7FMyat92i5CbFhxKnZOFzeaM2-3feik8rbsRAlHcrC4Zy4Tx5-aDTns8vbpyFhljFPMEr9hgAS7KigXnEuyh-rZkjA3A2c6HPbqOQsPkk8/s1600/IMG_6255.jpg" height="239" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNN0BrQqA6M5bQEIhumqIRMfHHOQ3mwg8ocz74NiMkrAEyBkxJGKoZWLyyW6KSC80ULg3f8JVzXkpS0wgVu1nU4QbA9naJsM5Pux-Qb_w4iTTjhe_ADRt9YzMpOWB6y2EBpphcbuPBQlk/s1600/IMG_6256.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNN0BrQqA6M5bQEIhumqIRMfHHOQ3mwg8ocz74NiMkrAEyBkxJGKoZWLyyW6KSC80ULg3f8JVzXkpS0wgVu1nU4QbA9naJsM5Pux-Qb_w4iTTjhe_ADRt9YzMpOWB6y2EBpphcbuPBQlk/s1600/IMG_6256.jpg" height="239" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj05or9OXSV_ipKwm_Gs5x5ganxXdRBj8Lt11yfJiQk41WtnYMCbcRQ_JPgrhZABUQ0FRA7VacL5kJymIKLikYjSPrbtJG-dEpzVGAENIqWIQorme_XCPNsD6rIS8C7EbH3dixE5ZwFIjw/s1600/IMG_6257.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj05or9OXSV_ipKwm_Gs5x5ganxXdRBj8Lt11yfJiQk41WtnYMCbcRQ_JPgrhZABUQ0FRA7VacL5kJymIKLikYjSPrbtJG-dEpzVGAENIqWIQorme_XCPNsD6rIS8C7EbH3dixE5ZwFIjw/s1600/IMG_6257.jpg" height="320" width="238" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">And here's it is in action..</span><br />
<iframe allowfullscreen="" frameborder="0" height="270" src="//www.youtube.com/embed/nJxlpu79WB0" width="480"></iframe>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-47595414506961589432014-01-26T21:26:00.002-05:002014-01-26T21:26:47.849-05:00Working on the Lifter and more computer work<span style="font-family: Verdana, sans-serif;"><b>The Lifter Mechanism</b></span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">This week I started working on the lifter mechanism that will give R2 the ability to show off the Life Form Scanner and Periscope. Another builder in Sweden has a very clever design that has great potential. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The trick is in Sweden everything in metric. Replicating the parts in a non-metric country is a bit of a challenge!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Since he was kind enough to give me the files in STL format, my Ultimaker 3D printer and its CURA software can print most of the parts with ease. However for something like this, I am not sure plastic is the best material.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWtqKwL_8ecng8vC1QKR2_u1UE00YAe09Rl4OVD9v_qvZPHGStyFCgHyZ6kfKaxmx-MUYk6Pyed1Q_7uZLF2xRitnzVyVnuUH2ygzn8ggRAuwnQsvOZJmSc_JTZND9am972j4xkHNm-PM/s1600/IMG_5903.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWtqKwL_8ecng8vC1QKR2_u1UE00YAe09Rl4OVD9v_qvZPHGStyFCgHyZ6kfKaxmx-MUYk6Pyed1Q_7uZLF2xRitnzVyVnuUH2ygzn8ggRAuwnQsvOZJmSc_JTZND9am972j4xkHNm-PM/s1600/IMG_5903.jpg" height="298" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9AQ2khca9Do5YNQeEfiNpHceA5hX-w-c-VpGG50a8oPxcXgom16rShOfIrxvoX7deh6V8JFwT2tuvihVAGRNgLlcpKXO35Kb50FmfYu2Tz75ROAmhrDNnM34pbMmebUU7jiCKReMnNtU/s1600/IMG_5906.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9AQ2khca9Do5YNQeEfiNpHceA5hX-w-c-VpGG50a8oPxcXgom16rShOfIrxvoX7deh6V8JFwT2tuvihVAGRNgLlcpKXO35Kb50FmfYu2Tz75ROAmhrDNnM34pbMmebUU7jiCKReMnNtU/s1600/IMG_5906.jpg" height="298" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlXO-wMP7dNmJRs5S4MoEd7FLmA67-2YjPsy03QqUPxG7bbfbN3cZQqwnlut_C5DyvCf3q-cuYua2RNvUHyDOjVEzvKvjD4ooJucG9RkU7edT8Pj_ijQ-5su3QlIGn82y5fuTelcp_Mfc/s1600/IMG_5917.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlXO-wMP7dNmJRs5S4MoEd7FLmA67-2YjPsy03QqUPxG7bbfbN3cZQqwnlut_C5DyvCf3q-cuYua2RNvUHyDOjVEzvKvjD4ooJucG9RkU7edT8Pj_ijQ-5su3QlIGn82y5fuTelcp_Mfc/s1600/IMG_5917.jpg" height="400" width="297" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">To make the parts in aluminum, we had to work a bit harder. Lars was kind enough to make the plans in DXF format, even though he had them all in Solid Works format. Solid Works, which I have the Academic Version, does not allow you to have the latest Service Packs. So, I could not view his files since he had a newer version. Anyways, asides Solid Works proving to be more an obstacle than an effective CAD tool, we switched programs to keep making progress.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">Then it was math word problems. In the USA, all of our materials are in Imperial. We can't go to the metal supply store and buy 5 mm thick material. The closest I had was 1/4 inch, which when measured, turned out to be 0.24 inch thick. That converts to 6.096 mm. For each part, I would have to mill away 1.096 mm of material. Sounds easy now but at the time, making all the tweaks in vCarve Pro and remembering to convert to metric...busy day of math problems! </span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTSAJ8dpDaqSQtMnc_3sTuBXB4ErkwRRyG2GFqdc_y4C_CIkn2UHwNVLixUTg2Bp-5TTVXmYXekJnbB3klonolB6e4zUWlp8Mxgw_3HWgRrz6FuWHcVKkqb6Kc3kDlkcdyxjeai_6oR-o/s1600/IMG_5919.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTSAJ8dpDaqSQtMnc_3sTuBXB4ErkwRRyG2GFqdc_y4C_CIkn2UHwNVLixUTg2Bp-5TTVXmYXekJnbB3klonolB6e4zUWlp8Mxgw_3HWgRrz6FuWHcVKkqb6Kc3kDlkcdyxjeai_6oR-o/s1600/IMG_5919.jpg" height="400" width="297" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipUYle1et8siuNeFyxulIkHzDsAhmwOMlJMkCI1R8x3tjStXUz2gLDqkSgwubn8QGJAp5fkJtRE827xZAaVt0OvNl3gXKOKKBbM-HsanEROekqXFGEAqmMZbmMwm5eXjRF6HfDTuM7GFQ/s1600/IMG_5920.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipUYle1et8siuNeFyxulIkHzDsAhmwOMlJMkCI1R8x3tjStXUz2gLDqkSgwubn8QGJAp5fkJtRE827xZAaVt0OvNl3gXKOKKBbM-HsanEROekqXFGEAqmMZbmMwm5eXjRF6HfDTuM7GFQ/s1600/IMG_5920.jpg" height="400" width="297" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc-c9_RKa1-nH-60X2mhSlYnDr70Tp0aPUNdj1w6Q3wOqL8qxmALKx841vYtGKSlEwwImGkGfs7qWajAfwECODNKAub6iB_F5shqA66ftzkyhWsQLWr2GDDczlQCvQUXsYJN7URPVwpdA/s1600/IMG_5965.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc-c9_RKa1-nH-60X2mhSlYnDr70Tp0aPUNdj1w6Q3wOqL8qxmALKx841vYtGKSlEwwImGkGfs7qWajAfwECODNKAub6iB_F5shqA66ftzkyhWsQLWr2GDDczlQCvQUXsYJN7URPVwpdA/s1600/IMG_5965.jpg" height="298" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The bracket pieces are currently bent but I want my welding friend to touch that up a bit. </span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The remaining parts are hard to source in the USA. The gear I found, but the Module 1.0 15 mm x 15 mm rack is proving to be a bit more of a challenge. Once I do get hold of the rack piece, I believe that will need some additional machining too. Since that is steel, the equipment I have access too will not be able to cut it. I'll need to recruit some help from a local shop for that. The servo, shaft adapter and motor are all ordered and en route!</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<span style="font-family: Verdana, sans-serif;"><b>More Intel NUC progress!</b></span><br />
<span style="font-family: Verdana, sans-serif;"><b><br /></b></span>
<span style="font-family: Verdana, sans-serif;">The new power converter was put to the test this week! Thanks to Intel replacing the NUC with a newer model that had the power connector, I tried it out. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The HDMI to VGA adapter that went bad was replaced under warranty (despite having to email incessantly to C2G and Tiger Direct to get them to SHIP THE REPLACEMENT. I can't give either high marks for customer service on this one.) </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">I ran on battery power for 25 minutes before shutting down, happy that there were no hiccups with the converter. According to the technical specs, the NUC will draw 13 watts at idle, 27 watts at load. I've been consulting with some electronic minds to get an idea on the best battery and size to consider for powering this PC.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-19870842711812236332014-01-12T22:03:00.000-05:002014-01-12T22:03:13.570-05:003D printing an adapter piece<span style="font-family: Verdana, sans-serif;">Tonight I finally got around to printing the part I needed to provide airflow to the NUC's power converter.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">I own SolidWorks (Academic) 2013 and despite going thru many wonderful tutorials on Lynda.com, I could not create the piece to my satisfaction.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Here's the plan: Take an old CPU cooling fan from an old Pentium Pro server and create an adapter piece so it can sit on top of the power converter enclosure.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">It sounds simple! The fan is a 50mm square and the enclosure is 43mm wide. I had several ideas on how to do this and I settled on one where two tabs would extend out from below the piece, so it could straddle the enclosure and be attached from outside. I'd leave the outside tabs intact, without a mounting hole, since I was not sure the best place for it to rest.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Several of my Ultimaker printer friends mentioned how quickly and easily they create things in SketchUp 2013. After viewing the video tutorials on Lynda.com (a fantastic resource!), I started working on my drawing...</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuEotT2iEzJ1L7-NrzMjanigPh9k2I4t9UR4vnOGV4bKe39_c-_D-xA3fMseD61lGhSsmA1TxWnn_fvykeWhlH_ZITKWeHWZcDSqP2k_fEJvo0_8fyns6pv09ATjXf7MtEUTRGJEazPZU/s1600/Capture2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="327" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuEotT2iEzJ1L7-NrzMjanigPh9k2I4t9UR4vnOGV4bKe39_c-_D-xA3fMseD61lGhSsmA1TxWnn_fvykeWhlH_ZITKWeHWZcDSqP2k_fEJvo0_8fyns6pv09ATjXf7MtEUTRGJEazPZU/s400/Capture2.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">The biggest complaint I have with SketchUp is when creating circles, you can key in the distance you want. The small holes are 4mm each, however the software, for whatever reason, enters in radius. Also, resizing an existing object is a bit less intuitive, requiring you to "rescale" it, and if the object has been extruded (thickness added), you have to make sure both sides of the hole are selected.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">In short, I struggled to make my simple part despite the "easy" interface. In both SolidWorks and SketchUp. Why? I think while watching the tutorials, I had my mindset on what I needed to make versus learning the principals well. In short, the impatient learner.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;">Once I had the part made, I had to Export it into a format the printer's slicing program, CURA, could use. The only modification I had to do was flip the part upside down.</span></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu-njz3Oqq2aw9C6OF_4xOHXU_k5eZhH3E63LIOkJ6BGk8nT6I_qhkotHEW4jxM9U6h22hDsC_aX6bBWfMTZw74skJdS7bz-OdvLr4iyo7Bxr4FGnEHHoxEv10ttRaJ1IV5x7T3fXrIlw/s1600/Capture.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="197" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu-njz3Oqq2aw9C6OF_4xOHXU_k5eZhH3E63LIOkJ6BGk8nT6I_qhkotHEW4jxM9U6h22hDsC_aX6bBWfMTZw74skJdS7bz-OdvLr4iyo7Bxr4FGnEHHoxEv10ttRaJ1IV5x7T3fXrIlw/s400/Capture.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
<span style="font-family: Verdana, sans-serif;"><br /></span></div>
<span style="font-family: Verdana, sans-serif;">Just over an hour later, I have the part completed.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLVzZCCVijw-h3hHGJmDA_WR43KxWOj_bUCtDogsdaJnLeNwUyUGTY46Xqxh_uyHNWvqHVA3bRVsBjlCASS1wBWP73_OK9xMSFU0gV_x0cHRoGqVgfPRMcHnwYXZ43Jj051Hlz8RymMBM/s1600/IMG_5851.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLVzZCCVijw-h3hHGJmDA_WR43KxWOj_bUCtDogsdaJnLeNwUyUGTY46Xqxh_uyHNWvqHVA3bRVsBjlCASS1wBWP73_OK9xMSFU0gV_x0cHRoGqVgfPRMcHnwYXZ43Jj051Hlz8RymMBM/s400/IMG_5851.jpg" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Next up is to see how the fan fits on it. It fits perfectly.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMO06NpCNnRA-kojGQcjUheGtVR8eIh7oQ0UoEJ63Uzku4H-Oe_-3yzfEPHBIyc5zS7te4JKb-l68HnS0NUZWXPAff0Wx6EKVybejmojnX69ssLwNrggIgHv8rUqrQmehStwTl1Ac7w_g/s1600/IMG_5858.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMO06NpCNnRA-kojGQcjUheGtVR8eIh7oQ0UoEJ63Uzku4H-Oe_-3yzfEPHBIyc5zS7te4JKb-l68HnS0NUZWXPAff0Wx6EKVybejmojnX69ssLwNrggIgHv8rUqrQmehStwTl1Ac7w_g/s400/IMG_5858.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihNWeDHNnKlHl6ugivg0ipI31ke0wnm0g6vpssEv9Q7ueW0fr2Ion92q6xK6oMTJKRZtb1GT6J3VU7uL5RF8Afm0BrFXTBgud4ErqltGaeBMF7Ng7P3WmadmVzzeTjFwdcQ5paRug0fSg/s1600/IMG_5859.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihNWeDHNnKlHl6ugivg0ipI31ke0wnm0g6vpssEv9Q7ueW0fr2Ion92q6xK6oMTJKRZtb1GT6J3VU7uL5RF8Afm0BrFXTBgud4ErqltGaeBMF7Ng7P3WmadmVzzeTjFwdcQ5paRug0fSg/s400/IMG_5859.jpg" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Now I can drill and mount this piece as needed! </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The Ultimaker 3D printer is proving to be a very useful tool in droid building.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-51581588781915874162013-12-29T22:03:00.001-05:002013-12-29T22:03:45.785-05:00Working on the computer and power converter<span style="font-family: Verdana, sans-serif;">I haven't posted an update since July and a question I am frequently asked is "How is the second R2-D2 coming along?".</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">I hope this entry answers that!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">R2-D2 #1 has had a very busy summer and fall, plus a <a href="http://paulsr2d2.blogspot.com/2013/12/helping-toys-for-tots-with-toy-raiser.html" target="_blank">Christmas time appearance to help out Toys for Tots</a>. Toss in work, on-line college classes and the usual busy life, spare time for the second droid has been sparse!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">But I am happy to post that with some holiday down time, I had a chance to work on R2's Intel NUC (Next Unit of Computing) PC and the Mini-Box DC converter.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">First, the NUC.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Part of the attraction of this device is the Intel i3 processor, which sips at the power. It is also an extremely small PC, popular with signage/multimedia displays, easily attached to the back of a monitor. It measures 4 inches x 4 inches and 2 inches thick.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifWnd-TCYni6edv3iTT9kwadWVrpJ_fJe_afr82nrkvu7i9vlAod0hfVUs05d6NlxfzXlG92Cc9Ni7iRBPU1TzAvQR-qElcMpLTcI3B2A-gDuM0BjhHSJbdZqNV7oHozT_HRH93h-6DU8/s1600/Capture2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="245" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifWnd-TCYni6edv3iTT9kwadWVrpJ_fJe_afr82nrkvu7i9vlAod0hfVUs05d6NlxfzXlG92Cc9Ni7iRBPU1TzAvQR-qElcMpLTcI3B2A-gDuM0BjhHSJbdZqNV7oHozT_HRH93h-6DU8/s400/Capture2.JPG" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZamV1WqnF-BqdS8vQRmYUzruQ9t5LharVdHOJDCs53VMjyQ0BE_O4v9nSDzhlc-jifv709j0P-potUbFfaOB1NoDT3b7eV9r_cjuDHm5_qqhvwHWaKC1IM_1IRSrBkIQzyqv8KHqA31Y/s1600/Capture.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="247" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZamV1WqnF-BqdS8vQRmYUzruQ9t5LharVdHOJDCs53VMjyQ0BE_O4v9nSDzhlc-jifv709j0P-potUbFfaOB1NoDT3b7eV9r_cjuDHm5_qqhvwHWaKC1IM_1IRSrBkIQzyqv8KHqA31Y/s400/Capture.JPG" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">It comes "barebones", meaning you purchase the amount of RAM you want, the size/capacity mSATA solid state hard disk and the WiFi adapter (optional). I put 8 gb of RAM, a 120gb SSD and went with the Centrino WiFi as well. Once you add it all up, you've spent about the same as a modestly equipped laptop.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The NUC uses 19 volts and has the optional power input directly on the motherboard (instead of using the barrel-plug connector on the back). My NUC sat around for several months before I realized mine was missing the connector. The documentation stated it should be there so I contacted Intel on their support site about the discrepancy. I was expecting to be told "too bad" since so much time had elapsed from my purchase. However, Intel contacted me, explained I had a very early version of the device and offered to RMA a replacement right away. I provided the model and serial number and they shipped the new one NEXT DAY AIR. <b>Amazing service!</b></span><br />
<span style="font-family: Verdana, sans-serif;"><b><br /></b></span>
<span style="font-family: Verdana, sans-serif;">With the replacement NUC here, I moved the RAM, SSD and Centrino wireless adapter to the new one. (Notice on the left side the 2-hole power plug just above the RAM. The previous NUC was missing this)</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhY-9y2pKJnu_gALQ_cMbiNwupQLyq3Gn1Y9vEWP1Key8eNnyoYSfNtFvVLPDlMj9rkZV0LqRDUci_lTpccT8P5aA_zOldlLPbpki3P5nI_YQ85lhJPZNXKHhLuxdpI2paCFabASNPfOMY/s1600/IMG_5756.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhY-9y2pKJnu_gALQ_cMbiNwupQLyq3Gn1Y9vEWP1Key8eNnyoYSfNtFvVLPDlMj9rkZV0LqRDUci_lTpccT8P5aA_zOldlLPbpki3P5nI_YQ85lhJPZNXKHhLuxdpI2paCFabASNPfOMY/s400/IMG_5756.jpg" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;"> After installing some updates to Windows 8, as well as numerous enhancements from Intel on the NUC, the computer is running great. </span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">My next goal was to make Windows 8 work more like Windows 7. No "charm" menu, getting the "Start" menu back and so on. Then my display turned green. I thought it was the start menu program I was using, but upon testing the monitor and trying a different HDMI cable, it was clear the VGA converter was the culprit. Even my BIOS screen went green-ish.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqWNn1wJSnqioKIMU1jmzy9GnZ8S2eeBphG6w0feu_SWIt1vMpJt4zRK-TH1egTH2wPNHsVBS-EyvMmKmzL-Br8rZv6uqfeJEY6AF602atElMOg2uNMYsZKxFQ8B7gy0JPrDrrEVsqO2o/s1600/IMG_5758.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqWNn1wJSnqioKIMU1jmzy9GnZ8S2eeBphG6w0feu_SWIt1vMpJt4zRK-TH1egTH2wPNHsVBS-EyvMmKmzL-Br8rZv6uqfeJEY6AF602atElMOg2uNMYsZKxFQ8B7gy0JPrDrrEVsqO2o/s400/IMG_5758.jpg" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The problem with the converter failing is it also acts as the audio output. You see, the NUC only has HDMI outputs. Now that's great if you are only plugging into a big screen TV that will play video presentations all day. But if you are using it in the role I have in mind, you need have audio output into R2's amplifier/speaker system. R2 also had a small LCD sceen tucked behind one of the body panels and that uses VGA. With the converter failing, I've put out some emails to find a reliable solution.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMXfU5uctkxdE1qkdpN0tjWXtKosZU7bFKroLe7ZsIEYGar0rKtF08k4oCtr7waE1wdrIfV5hKVdqv_n2YcS-xBLwqxVB27ZP8XlxBkEvRhEDQU3nOqCSc0TVzcD_jgd-vakJYVTvgBAc/s1600/IMG_5767.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMXfU5uctkxdE1qkdpN0tjWXtKosZU7bFKroLe7ZsIEYGar0rKtF08k4oCtr7waE1wdrIfV5hKVdqv_n2YcS-xBLwqxVB27ZP8XlxBkEvRhEDQU3nOqCSc0TVzcD_jgd-vakJYVTvgBAc/s400/IMG_5767.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">HDMI converter. HDMI goes in, the jack on the right provides the audio port needed for the sound, then the blue connector is the VGA connection to the LCD display.</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">Since my progress seems halted on the computer for the moment, I decided to make sure the DCDC-USB-Pro is going to work alright.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The converter is a slim, well documented power converter, which will take 12 volt power and make it 19 volts for the NUC. Jumper settings or the USB software allow you to precisely set the desired voltage, plus other options I'll cover another time.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigjuxcTkl5Xv7Ijok0fzYURJ_uBHff8WScoN9OreSbQNPPoXDECxAqRaI3sZgRyHutDHjfsA87v6gZx2_YdFwyGEFvxQhMvvLXPYylnmg8Kbfw_R_ej7okbCkrqWjFUctkWtaPjQQH4HM/s1600/IMG_5765.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigjuxcTkl5Xv7Ijok0fzYURJ_uBHff8WScoN9OreSbQNPPoXDECxAqRaI3sZgRyHutDHjfsA87v6gZx2_YdFwyGEFvxQhMvvLXPYylnmg8Kbfw_R_ej7okbCkrqWjFUctkWtaPjQQH4HM/s400/IMG_5765.jpg" width="400" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">Once thing I forgot to order when I bought it was the 4-prong to 2-prong connector, so I did that this weekend. I can't find the cable anywhere locally and as much as I hate buying a $2 part that costs more to ship, I had to!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The enclosure is a nice touch. I need to add a fan so things are kept cool. The only concern I have so far is that when set to 19 volts, my tester shows 22 volts. I don't know if my meter is a bit off or if variation is normal. I emailed Mini-Box to get a definitive answer and until I know for sure, won't attempt to power the NUC with this yet.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">So in summary, I am making progress! I need to figure out the video/audio output concerns of the NUC, then the voltage questions of the converter.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">More soon!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-34449031604481006922013-07-04T00:04:00.000-04:002013-07-04T00:04:25.138-04:00Center Leg Lift Development: An Overview<span style="font-family: Verdana, sans-serif;">One of the toughest things to replicate from the STAR WARS movies is what we call "232". </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">2 stands for 2-leg mode, when R2-D2 is standing upright. Then, R2 transitions into 3-leg mode. The body pivots, the center ankle/foot is extended out of the body and R2 is now in its driving mode. When R2 gets where it needs to be, it returns to 2-leg mode. Thus, "232".</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Here's a video clip I pieced together that shows this effect in the original STAR WARS movie...</span><br />
<br />
<iframe allowfullscreen="" frameborder="0" height="344" src="//www.youtube.com/embed/ub7edgRMXwg" width="459"></iframe>
<span style="font-family: Verdana, sans-serif;"> </span>
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Many of us R2 builders have tried to pull off this effect in a variety of ways. Some have specifically built their R2s out of much lighter materials, like wood or styrene, to make the movement easier to articulate. </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">There are several aspects that make the 232 system. </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">1) The shoulders. These need to pivot 17 degrees for R2 to be in 3 leg mode. The mechanism to do this needs to rotate the entire weight of the droid precisely. If one side doesn't move smoothly with the other, damage could occur.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhfVlMehAY6pcWl7ExJnk7loSUrWMOUiyN6JTQpjJNRXMpri3XLqi2qRKbRoeautXkHTMtoUeVEu01H86T_chsq_M4wlneDdncL1KhvdIj1vaNERwTKCcshA8G6pOJQQJFj92XQylovzw/s600/IMG_3122.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhfVlMehAY6pcWl7ExJnk7loSUrWMOUiyN6JTQpjJNRXMpri3XLqi2qRKbRoeautXkHTMtoUeVEu01H86T_chsq_M4wlneDdncL1KhvdIj1vaNERwTKCcshA8G6pOJQQJFj92XQylovzw/s400/IMG_3122.jpg" width="297" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Shoulder linkage and linear actuator</td></tr>
</tbody></table>
<br />
<br />
<span style="font-family: Verdana, sans-serif;">2) The center leg lift. (This is what I am working on.) As you see in the video clip above, the center ankle and foot need to fit inside the body. Then, it needs to smoothly extend out and be prepared to handle the load placed on it. It needs to deploy quickly, as seen in the movie. This is a challenge since most modern linear actuators that can handle 150 pounds or more have travel speeds of 1/2 an inch per second. With the ankle and foot size taken into consideration, my setup travels 8.5 inches. However, when you take into account gravity and the weight of the ankle/foot and wheels inside it, that could be a bit quicker.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIuX2roI-Zeyl1HwIJAbKfMttwNgvprfFSoKLJxIZE7jBuuKfRvAlDiY7r2BV0ggKhggYM75QLATO5V6E6I3QV2BXtdplWfXwdpNETOfTl5UX_Q5jG6p3Au0_420sFrqKNYTk1HB1NS84/s1600/IMG_4190.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIuX2roI-Zeyl1HwIJAbKfMttwNgvprfFSoKLJxIZE7jBuuKfRvAlDiY7r2BV0ggKhggYM75QLATO5V6E6I3QV2BXtdplWfXwdpNETOfTl5UX_Q5jG6p3Au0_420sFrqKNYTk1HB1NS84/s400/IMG_4190.JPG" width="298" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Center leg lift setup I'm working on</td></tr>
</tbody></table>
<br />
<br />
<span style="font-family: Verdana, sans-serif;">3) Locking the ankles. R2's ankles, where they attach into the foot, are triangular and bolt into a channel in the foot. Many lighter droids can stay in 2-leg mode simply because they do not put nearly as much force on the joint. A 200-pound aluminum robot is a different story!</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrfbbZl12Uba7E3rrK4Iash_xYWRBPGbp8-4M7TCw6VOeDjWoj5TWQdL1ZhKB9hLooAVGsxlei0Ftumluf6y9yBko_nVNG5V7KCdKEfpOboJar65DEbYCfhZxKwPLnCxKSfLENs_0haTA/s640/IMG_0419+(Small).JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrfbbZl12Uba7E3rrK4Iash_xYWRBPGbp8-4M7TCw6VOeDjWoj5TWQdL1ZhKB9hLooAVGsxlei0Ftumluf6y9yBko_nVNG5V7KCdKEfpOboJar65DEbYCfhZxKwPLnCxKSfLENs_0haTA/s320/IMG_0419+(Small).JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Note how the ankles are triangular in shape with a single hole mount point to pivot</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIdQ2hXDZjf-xgDCXDY5GyRZehZnnlcXgEG0b2pCJBucHwA4dKzIUd85wfEc-naPYQNpq5FIJk0tJYBo4opgVNWL-aFCvsokIWZmLYcasTkMgJKoJMVzysnluk3SxVj12p_BTW3Avf_sM/s1024/016.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIdQ2hXDZjf-xgDCXDY5GyRZehZnnlcXgEG0b2pCJBucHwA4dKzIUd85wfEc-naPYQNpq5FIJk0tJYBo4opgVNWL-aFCvsokIWZmLYcasTkMgJKoJMVzysnluk3SxVj12p_BTW3Avf_sM/s320/016.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Ankle freely travels in the foot. This needs to be secured for proper movement in a 232 setup.</td></tr>
</tbody></table>
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Locking the ankles is challenging. There isn't much room inside the ankle, or the foot, to put much in there. The foot is already largely off limits since the foot motor/drive system is in there. And this is probably the toughest piece of the puzzle, since R2 can't go back upright until those ankles rotate.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">So you now have the basics of what 232 is all about. In my next post, I'll show you how the center leg lift is coming along!</span><br />
<span style="font-family: Verdana, sans-serif;"> </span><br />
<span style="font-family: Verdana, sans-serif;"> </span><br />
<br />Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-48632240465195765662013-05-05T00:41:00.000-04:002013-05-05T00:41:17.896-04:00Modifying the frame for the COM-8 Rear DoorToday I received the Rear Door Assembly from COM-8 down in Texas. COM-8 (James) makes frames and accessories for them. The frames are very similar to the ones offered by Jerry Greene (JAG) a couple years ago. JAG passed the frame building torch to him and COM-8 offers R2 builders some nice, bolt together packages for those who prefer aluminum frames for their droid builds.<br />
<br />
While the frames are similar in lineage, my JAG version 5 frame needed some minor tweaks to install the Rear Door Assembly (RDA)<br />
<br />
The RDA will give me a swing out door, essentially. Also, the space that is currently left open for a flip down electronics tray, I can utilize to mount things into this new structure.<br />
<br />
The parts come anodized blue and COM-8 includes a detailed instruction manual. <br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtM9H3qpZeKArGFWwuWlGmgQ4kO_Pyj4B4k8MeKoE0G97zMtwSpF7JveKdGbzYBNQJ7o6mPqJWw63IPr5pIhOfcyWwpb-hE-DKCveLNEyuFX_-Ik0b5GmtFSUaOgiYQmrTWRTu3uMd4XE/s1600/IMG_3373.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtM9H3qpZeKArGFWwuWlGmgQ4kO_Pyj4B4k8MeKoE0G97zMtwSpF7JveKdGbzYBNQJ7o6mPqJWw63IPr5pIhOfcyWwpb-hE-DKCveLNEyuFX_-Ik0b5GmtFSUaOgiYQmrTWRTu3uMd4XE/s320/IMG_3373.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<br />
The best tip in the manual is keeping track where the engraved "H" is!<br />
<br />
Assembly goes along pretty quick from there<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9yLtZk1jN2RUV4Gz6n8e_8_xu8mRBsBR368hD7702S7IwuypqElAedt0-UZ-6-6lHEhbMLciIDGzPZWFGnnJsrmrnatETj4AzSHPB0PhrhzUuwcc4bG7eDoTnXHwPpfbpJc9r0cTSgxQ/s1600/IMG_3374.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9yLtZk1jN2RUV4Gz6n8e_8_xu8mRBsBR368hD7702S7IwuypqElAedt0-UZ-6-6lHEhbMLciIDGzPZWFGnnJsrmrnatETj4AzSHPB0PhrhzUuwcc4bG7eDoTnXHwPpfbpJc9r0cTSgxQ/s320/IMG_3374.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz3bklbHD5If1StfsvR5itN51U4lPGmU4qfH0A-2BH5T28B0rZfm5lFvUmu3ffgn8S8W1WFqlj5p5U837z5wAwoLyMVEsvAqJDomaiKfPzk6WBBZQwQvo6m1n5YlQSy_u34ImZmlxaUlA/s1600/IMG_3375.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz3bklbHD5If1StfsvR5itN51U4lPGmU4qfH0A-2BH5T28B0rZfm5lFvUmu3ffgn8S8W1WFqlj5p5U837z5wAwoLyMVEsvAqJDomaiKfPzk6WBBZQwQvo6m1n5YlQSy_u34ImZmlxaUlA/s320/IMG_3375.jpg" width="238" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOoV27SnHbw6NN0D-9gOm_uH9Pgv4zTvVYRYPBwmboVc66YKE2OzGfz8gjtBrSUhkiBmeSBhi0zOlH-pG6gpijy_Rumveag9RqJJHBpxPoCBUEzhEqgOdpW0gUEASbqbHYqal0y1r9x6I/s1600/IMG_3376.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOoV27SnHbw6NN0D-9gOm_uH9Pgv4zTvVYRYPBwmboVc66YKE2OzGfz8gjtBrSUhkiBmeSBhi0zOlH-pG6gpijy_Rumveag9RqJJHBpxPoCBUEzhEqgOdpW0gUEASbqbHYqal0y1r9x6I/s320/IMG_3376.jpg" width="320" /></a></div>
<br />
<br />
<br />
For the JAG frame, the vertical rods in the back will need to be removed since the included ones will replace them.<br />
<br />
The JAG frames use the Inner holes in the frame ring....<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj6LIpXJjwoxNjvlLL6OtZDsIu9TuNMkcYko8pMGDyjlY4MsuA7fUsj9_QFLf9NRAuJV4VTeanwwHCyH5GVs3MxqlRSrfu-gPGYVymw1DQLjCiLPLCgFO3VA3Yt8lQIo_6dKKR43y52qw/s1600/IMG_3377.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj6LIpXJjwoxNjvlLL6OtZDsIu9TuNMkcYko8pMGDyjlY4MsuA7fUsj9_QFLf9NRAuJV4VTeanwwHCyH5GVs3MxqlRSrfu-gPGYVymw1DQLjCiLPLCgFO3VA3Yt8lQIo_6dKKR43y52qw/s320/IMG_3377.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The threaded rod needs to be removed from the JAG frame. The hole below it is what the COM-8 frames use and we will use to install the RDA</td></tr>
</tbody></table>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzSgc0fTpOUZZ_Wsgo-1cK7hgXiKh3_kFz1UUPQuthkJlk9U9wBZpSa0VGdRXljj01pc91m3LqRgKkVdJnPxH7qLAK0Orbs3TbW2CdZ7PpgALHBZyxr9ZdZFVH44L68zIdoZ8hQ7SVowM/s1600/IMG_3378.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzSgc0fTpOUZZ_Wsgo-1cK7hgXiKh3_kFz1UUPQuthkJlk9U9wBZpSa0VGdRXljj01pc91m3LqRgKkVdJnPxH7qLAK0Orbs3TbW2CdZ7PpgALHBZyxr9ZdZFVH44L68zIdoZ8hQ7SVowM/s320/IMG_3378.jpg" width="320" /></a></div>
<br />
Once the threaded rods are out, I countersunk the hole so that in its place, a 1/4-20 flat head screw could be installed. It has to be extremely flush as the hinge of the RDA will go over it.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxLDwHeIBRo932qjvdrxQZ2oc_reZWMlhHg8BmVSzODJFhy1GQkzqVTyrkrDCyu4tPUqu96wtTSlfpeDgeq1gdJRX_9ZovzHwQMf40317yPgbJHyvgp_2PKEKjUz9nQwYxKk58QPP5pIk/s1600/IMG_3379.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxLDwHeIBRo932qjvdrxQZ2oc_reZWMlhHg8BmVSzODJFhy1GQkzqVTyrkrDCyu4tPUqu96wtTSlfpeDgeq1gdJRX_9ZovzHwQMf40317yPgbJHyvgp_2PKEKjUz9nQwYxKk58QPP5pIk/s320/IMG_3379.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
Thankfully the holes were already there on my frame, with the exception of one, which took my friend a few moments to drill out, then countersink<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4fcf44HoJlnzENiRotBonMvlS1NmJuntSP4F3sZMGJ3Ld15B6W097npR6NTrdifkOGbz8X9OlhziiTY0lqJvAoNS0kQc0uQmGBXyoagRh8WBcLxi1hubl4ntJxhTUPbVu63qcfdJ9P9Y/s1600/IMG_3381.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4fcf44HoJlnzENiRotBonMvlS1NmJuntSP4F3sZMGJ3Ld15B6W097npR6NTrdifkOGbz8X9OlhziiTY0lqJvAoNS0kQc0uQmGBXyoagRh8WBcLxi1hubl4ntJxhTUPbVu63qcfdJ9P9Y/s320/IMG_3381.jpg" width="238" /></a></div>
<br />
Now it was time to install the RDA assembly...<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ8Sm9d2YcL5lrrPga9W01ISHQ6wdLFJLBARERZq8DBUK4jwshmUzFlySLrPen2MNZ-YSByAoFSJX780f6NTJL0Bzm-EdXBMT0NqaWkrNya-q-ZiUwVA7X2Mgdnws9vBKga3ne3WYvnJw/s1600/IMG_3382.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ8Sm9d2YcL5lrrPga9W01ISHQ6wdLFJLBARERZq8DBUK4jwshmUzFlySLrPen2MNZ-YSByAoFSJX780f6NTJL0Bzm-EdXBMT0NqaWkrNya-q-ZiUwVA7X2Mgdnws9vBKga3ne3WYvnJw/s320/IMG_3382.jpg" width="238" /></a></div>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNXfG5NIslT6hOis3sGTqDtmvUjWipOGcJbrcBBotX5IpP3TbBTKbZXLEgvMfGstiqKeN1YwPY-P8sfbm2CbI2SUtPuMtlGV0hVRpJRgV9DmEOrg5NfFYvxf_58FDu5xuZxmLRJzhsadM/s1600/IMG_3385.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNXfG5NIslT6hOis3sGTqDtmvUjWipOGcJbrcBBotX5IpP3TbBTKbZXLEgvMfGstiqKeN1YwPY-P8sfbm2CbI2SUtPuMtlGV0hVRpJRgV9DmEOrg5NfFYvxf_58FDu5xuZxmLRJzhsadM/s400/IMG_3385.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The larger spacer goes up top while the lower part sits flush on the frame ring.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjro18OflIGfDi2-oUsXpX2fcaRfKRcWIihvdL2rq3Arjp47uGFxS9GzAL2R_YtWFWe0Tz9htcvVWqZNoBVwbS3d7XpYJ1CLfFJbJm2nqdCpVJe0hGPE33Hg7vx-P8TYmCbdSxLo1Vi_io/s1600/IMG_3390.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjro18OflIGfDi2-oUsXpX2fcaRfKRcWIihvdL2rq3Arjp47uGFxS9GzAL2R_YtWFWe0Tz9htcvVWqZNoBVwbS3d7XpYJ1CLfFJbJm2nqdCpVJe0hGPE33Hg7vx-P8TYmCbdSxLo1Vi_io/s400/IMG_3390.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">....and here it is, aligned and works fine!</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<br />
<br />
<br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-9683503781881782562013-04-07T22:33:00.000-04:002013-04-07T22:33:13.264-04:00Mounting the shoulder actuators<div style="text-align: justify;">
Over the past few weeks, I've been working with my machinist friend on some ideas on installing the linear actuators into R2's frame. Originally the shoulders were designed to work with an actuator with a 3 inch stroke but the shoulders actually have a bit more movement than that...about 3.4 inches. The way the shoulders work, the four bolts rotate thru the grooves. They all for the shoulders to rotate back, when in 3-leg position and upright, in 2 leg. They also also for a few degrees to tip forward, allowing us builders to articulate and create "body rocking/body movement".</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUNeW5Vd9flSQtdeqkG5gmdybzup_qfWToC9Ab9w9Pubw1qylIBwS-Slrde0UfntSCfRfZYFsUkKUO_Hp1PIO2lgQt61v219o24Ybfm06TBfrBgmAgMHBfoShjUtiAd3ttlc_vK6aWP4c/s1600/Capture.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUNeW5Vd9flSQtdeqkG5gmdybzup_qfWToC9Ab9w9Pubw1qylIBwS-Slrde0UfntSCfRfZYFsUkKUO_Hp1PIO2lgQt61v219o24Ybfm06TBfrBgmAgMHBfoShjUtiAd3ttlc_vK6aWP4c/s320/Capture.JPG" width="213" /> </a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: justify;">
I decided to go with 4 inch stroke actuators equipped with potentiometers. In the closed position, they will put R2-D2 in it's 3-leg position. Since the stroke is larger that the movement allowed (3.4 inches), I will use the data from the potentiometers to stop them before they exceed the travel allowed. </div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDrryHcssuzbhe1v_E55vR1em4JnnvQ1o8SwPjZq73kZlxhWAYupcF4GOEKtiGufdfcN7CbopNCexc7md7237N80btPJGHDsNxynD7H08ruquXpphYpsxbOPUD3BxcqZbspm9unJc5NoM/s1600/IMG_2952.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDrryHcssuzbhe1v_E55vR1em4JnnvQ1o8SwPjZq73kZlxhWAYupcF4GOEKtiGufdfcN7CbopNCexc7md7237N80btPJGHDsNxynD7H08ruquXpphYpsxbOPUD3BxcqZbspm9unJc5NoM/s320/IMG_2952.jpg" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: justify;">
Attaching the actuators to the shoulder levers went fine, although we decided to use a 1/4-20 sized bolt.</div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxWV77heoHz9Wb1-Y8kkGRxiyh6uPDaqhzP8iirzIEXxP4Gpbj9XUVGUR2QBPv3tT6luP4O5u6U4S8PhdYRYmclCRmXHabezr3u0uEOgvmChzBX01bZQfuSXVTeersaoDUCUFr5Hwe6m8/s1600/IMG_2980.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxWV77heoHz9Wb1-Y8kkGRxiyh6uPDaqhzP8iirzIEXxP4Gpbj9XUVGUR2QBPv3tT6luP4O5u6U4S8PhdYRYmclCRmXHabezr3u0uEOgvmChzBX01bZQfuSXVTeersaoDUCUFr5Hwe6m8/s320/IMG_2980.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: justify;">
</div>
<br />
<br />
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: justify;">
Since the potentiometer equipped actuators are longer than the original design, we had to come up with a way to fit them into the frame. Before we could snub them into the lever, we had to do something about the bottom attach point. We want the actuator to be straight for its vertical lifting and retracting.</div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVnOvHYtqeZPA1LBUpCFXQ_RWpDJEhm48gCYrBH3yOz-wYgsNmx8RIAPePYjAOY51qq83xGTRmE5SCpDYJXfFynIyaCrlXL5ZRfHNf-Yqwhl0Lwmz41sJA7_F3NBnGQ0xtlkNNsZPqvmE/s1600/IMG_2958.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVnOvHYtqeZPA1LBUpCFXQ_RWpDJEhm48gCYrBH3yOz-wYgsNmx8RIAPePYjAOY51qq83xGTRmE5SCpDYJXfFynIyaCrlXL5ZRfHNf-Yqwhl0Lwmz41sJA7_F3NBnGQ0xtlkNNsZPqvmE/s320/IMG_2958.jpg" width="238" /></a></div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: justify;">
To overcome this, we did two things: We made mountings to bolt under the frame ring and small cut outs for the actuators to mount straight.</div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4qiOZelP6MUof7NmXB7-sUWZT1wtGbSmgUFCdq8oY4ht7YJBzh-Q8aqRqdQsC8_NIinwYoNPmcTLrp1vXcHOYpyk2o_C919nzOU3wtJOegFYTWTPLAhJpySxc570Jwd0Kg8AZJEXvPBQ/s1600/IMG_3106.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4qiOZelP6MUof7NmXB7-sUWZT1wtGbSmgUFCdq8oY4ht7YJBzh-Q8aqRqdQsC8_NIinwYoNPmcTLrp1vXcHOYpyk2o_C919nzOU3wtJOegFYTWTPLAhJpySxc570Jwd0Kg8AZJEXvPBQ/s320/IMG_3106.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpYqAhxeChZqYwycfVk5IThEEyLKN9K6z-eQ3Lg8ZnKk0VI84ZDx_Spz0XzFjRhNMI2GZdYiUpSQccoe9xtozU_WYUkNlHg1halCzPayAFSmV1wYU3W6xY0TsZyloZxPIBxnB_Vs-iwr4/s1600/IMG_3110.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpYqAhxeChZqYwycfVk5IThEEyLKN9K6z-eQ3Lg8ZnKk0VI84ZDx_Spz0XzFjRhNMI2GZdYiUpSQccoe9xtozU_WYUkNlHg1halCzPayAFSmV1wYU3W6xY0TsZyloZxPIBxnB_Vs-iwr4/s320/IMG_3110.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivCHK3DI3Ts5_zfU_5Vr2zLIxMhjguroeOp9TamEdn1npQZndAZvgV0vezrao0EkslK7Gg0yrHzO-Gpu1d_CdygqrdS8hM4OWXBtYzWoyC9s648vFfagqkDn46QuT0_FxXyZliYvvYJcg/s1600/IMG_3107.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivCHK3DI3Ts5_zfU_5Vr2zLIxMhjguroeOp9TamEdn1npQZndAZvgV0vezrao0EkslK7Gg0yrHzO-Gpu1d_CdygqrdS8hM4OWXBtYzWoyC9s648vFfagqkDn46QuT0_FxXyZliYvvYJcg/s320/IMG_3107.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnI5534ABglwM9km48IjMhfwPxzT4o-EWV7rSe6xNUmRZUXxLqir4Sr9E2bM7KupLtkkkGTWAFyyCR9BM1hCZEHkm9uYtGIgdzw3X5dwNXCte-GV5n7kUQQBaYtWru_Y77hFgdyuz1zrg/s1600/IMG_3114.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnI5534ABglwM9km48IjMhfwPxzT4o-EWV7rSe6xNUmRZUXxLqir4Sr9E2bM7KupLtkkkGTWAFyyCR9BM1hCZEHkm9uYtGIgdzw3X5dwNXCte-GV5n7kUQQBaYtWru_Y77hFgdyuz1zrg/s320/IMG_3114.jpg" width="238" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8vu1P5i6esxxJ1joEWKbNLYfeWdJ5IwolUCrcK4hITW-rftfKoJ-opMmB5IpQladv24Ebj97po62r0yXaHhhFvAjMKCmIkczlnIBZzHGEc9FhyphenhyphenA4hFgXHzfbjHkyvVN0bcCZIOPKlBuI/s1600/IMG_3122.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8vu1P5i6esxxJ1joEWKbNLYfeWdJ5IwolUCrcK4hITW-rftfKoJ-opMmB5IpQladv24Ebj97po62r0yXaHhhFvAjMKCmIkczlnIBZzHGEc9FhyphenhyphenA4hFgXHzfbjHkyvVN0bcCZIOPKlBuI/s320/IMG_3122.jpg" width="238" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg43qnYleX7UeByeasz1BxsPWKVwcp0obfdmzTCr-vaUmrY6rDJ-SyA66EaMsgVzyj0LE2LewZq7YtSmBhoMwHs-u6h_9oMpbtjARPGpmxMw68EoSv6TZoQl5GAKB0fAVXpN5Twl_dKbxE/s1600/IMG_3123.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg43qnYleX7UeByeasz1BxsPWKVwcp0obfdmzTCr-vaUmrY6rDJ-SyA66EaMsgVzyj0LE2LewZq7YtSmBhoMwHs-u6h_9oMpbtjARPGpmxMw68EoSv6TZoQl5GAKB0fAVXpN5Twl_dKbxE/s320/IMG_3123.jpg" width="238" /></a></div>
<div class="separator" style="clear: both; text-align: justify;">
</div>
<br />
<br />
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<div class="separator" style="clear: both; text-align: justify;">
With that side done, it was on to the next....and now, the actuators are both installed!</div>
<div class="separator" style="clear: both; text-align: justify;">
<br /></div>
<br />
<br />
<br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-12896299611626842362013-03-23T20:24:00.001-04:002013-03-23T20:24:34.036-04:00Dome gear, dome drive and moreOver the past week or two, I have been working on making more progress on R2-D2 #2.<br />
With the dome plate made, it was time to make a dome gear out of aluminum, as I had done for the first droid.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNkes9pbsbSIEda3pnWrpEI5Gf8ikhuFLd826_EuSHZIdu1CfankYNHpNzNNriLB2lN1IE7KXl5AcFXxGn9NKHH6ObdxS4Su6TkuODmj5caf8R7Zf-SK7DLwP7ZupZWZ49kxyUgBCpBJk/s1600/IMG_2851.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNkes9pbsbSIEda3pnWrpEI5Gf8ikhuFLd826_EuSHZIdu1CfankYNHpNzNNriLB2lN1IE7KXl5AcFXxGn9NKHH6ObdxS4Su6TkuODmj5caf8R7Zf-SK7DLwP7ZupZWZ49kxyUgBCpBJk/s320/IMG_2851.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHAj1OvKVmua21V0m2j8IrJQG6S2I3o-znXJn2P_szgvQX3SjXBuOj4oj8zzNpgKZ3MgjHziwu2I6S7XiZiweLkgZoODDdbuDGk2sAeb5CGjoMXjJJ64kv1XSp6xXr5lo1cMSTVgQyfk8/s1600/IMG_2853.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHAj1OvKVmua21V0m2j8IrJQG6S2I3o-znXJn2P_szgvQX3SjXBuOj4oj8zzNpgKZ3MgjHziwu2I6S7XiZiweLkgZoODDdbuDGk2sAeb5CGjoMXjJJ64kv1XSp6xXr5lo1cMSTVgQyfk8/s320/IMG_2853.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRwKKrf6pSMFI89cekHoJIPPmWekf-zjXboAUd_0zMxDXXEuCavLKqVznAUwxGebSQ3aST-zFgxFEbIRAlK-kecPxUnP8BQjkBtV72nWPFTlr3x7I1veJuOL4csat7UXr-HFun1XKVHM4/s1600/IMG_2879.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRwKKrf6pSMFI89cekHoJIPPmWekf-zjXboAUd_0zMxDXXEuCavLKqVznAUwxGebSQ3aST-zFgxFEbIRAlK-kecPxUnP8BQjkBtV72nWPFTlr3x7I1veJuOL4csat7UXr-HFun1XKVHM4/s320/IMG_2879.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
I cleaned up the dome gear some and my friend, Fred, insisted it should be shinier, so he hit it with some steel wool.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3SLSQHvJZ00_FStDeYzklfIjmin10E429GwFVFLEUZAGf09fIT1T5HMp4ylHW-cwnc9lsF0Gwtfeel9PacJOzR9g7VSdBKYIk1f0nEyXExjxzA1_DHPSshZjSAkPIHNQJ4cJT-iRYkRY/s1600/IMG_2904.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3SLSQHvJZ00_FStDeYzklfIjmin10E429GwFVFLEUZAGf09fIT1T5HMp4ylHW-cwnc9lsF0Gwtfeel9PacJOzR9g7VSdBKYIk1f0nEyXExjxzA1_DHPSshZjSAkPIHNQJ4cJT-iRYkRY/s320/IMG_2904.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
For better clearance for the dome drive sprocket to spin under the dome gear, I added a washer to each spot the mounting screws came thru.<br />
<br />
I'm using the <a href="http://www.pololu.com/catalog/product/1105" target="_blank">Pololu 37D 67:1 motor which turns at 150 rpm</a>.<br />
<br />
We cut a sprocket out of Delrin (plastic) and used the hole pattern for the <a href="http://www.pololu.com/catalog/product/1083" target="_blank">motor hub that Pololu sells</a>.<br />
<br />
To mount the motor, I used the <a href="http://www.pololu.com/catalog/product/1084" target="_blank">Pololu motor bracket</a>. I just flattened it out and drilled some holes to attach it to the metal frame ring.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxsxHidIbShf-NC67eAAjMRFu9l-6vU_57GK37UWSqtoWmrao0sqcpQg-yeaqbdgS-EIcm4heWt53N0f3BxUINFwBHQDnJXti5ialcTsu4RiPlz6j9IwhWYgvASsLRRJVYNyvSquOAK7U/s1600/IMG_2912.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxsxHidIbShf-NC67eAAjMRFu9l-6vU_57GK37UWSqtoWmrao0sqcpQg-yeaqbdgS-EIcm4heWt53N0f3BxUINFwBHQDnJXti5ialcTsu4RiPlz6j9IwhWYgvASsLRRJVYNyvSquOAK7U/s320/IMG_2912.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf2hoT7RVRpt1Tp-NqEelozDm9Y_BXE6VRdr_4EAiiS0FiMFwX5fp-XfAPOUVfzKg2rMWhoX0osSy3oQ-opkySjCoPJbDWnIjAqukcewFZdYKjciEOWCqNp6dTizzg_NxADxXet0leo6g/s1600/IMG_2910.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf2hoT7RVRpt1Tp-NqEelozDm9Y_BXE6VRdr_4EAiiS0FiMFwX5fp-XfAPOUVfzKg2rMWhoX0osSy3oQ-opkySjCoPJbDWnIjAqukcewFZdYKjciEOWCqNp6dTizzg_NxADxXet0leo6g/s320/IMG_2910.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3aFbndHFaW3TGzk7zBBJCAWcE7fWjrahgFRONNbag7prve235IciMlvB4ZmCK9o6TCL8pDPKeeUltdSEopC75NF7vLHHDnJgWumTkcwKhSgV-BZ34-Jgow7lF9bwBhK1_bV2FleJ8kTs/s1600/IMG_2909.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3aFbndHFaW3TGzk7zBBJCAWcE7fWjrahgFRONNbag7prve235IciMlvB4ZmCK9o6TCL8pDPKeeUltdSEopC75NF7vLHHDnJgWumTkcwKhSgV-BZ34-Jgow7lF9bwBhK1_bV2FleJ8kTs/s320/IMG_2909.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
And here it is in operation...<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dyJRJtW5f9fB6WenFooqWeQ3xdwXY3ZoNx-zpgmUC3pjht8mYnx8uZkubhkyFbubrexkDR00RH97CpL62FY9A' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
<div style="text-align: center;">
<br /></div>
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-2385122748428046952013-03-10T19:10:00.000-04:002013-03-10T19:10:07.846-04:00Making a [very cool looking] Dome Plate As I get the second R2-D2's build back on track, one piece I did not have was the dome plate. This is the part where all of the gadgets will mount to inside R2's dome. For example, the periscope, the life form scanner and other things.<br />
<br />
The one I have in the first R2 is a 1/8" inch thick dome plate. While it works fine, I wanted something thicker the next time around. <br />
<br />
The great thing about being part of an R2 Building Club is the way people share their ideas with one another. Another builder shared with me a drawing of a dome plate that was really well laid out and looked great. Using the 1/4" inch aluminum, it has numerous grooves, holes and cut outs that reduce the weight of the finished piece.<br />
<br />
Once I had a chance to review the drawing with my machinist friend, it was pretty clear we had a good amount of work ahead of us. We had to tell the software what to cut thru, what parts to cut down an 1/8" of an inch, where to place tabs and so on. This took about two hours to do. Once we were happy with the calculations and previews of the end result, we created the g-code for the Mach 3 software. The Mach 3 software takes that code and controls the X, Y and Z axis of the CNC machine.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBohfXsSsdOPehONm9_wTBZyCRwisgz9aJ3dCkffJnBa0VPZI5ACFzCTmoxct9mKGS2X4az5dhCXws75AREB4coWJWosfJUBYQ8MO0WnxciXPxhmstxFRQWb8M3OKTBjAi2clCr6maFv4/s1600/IMG_2802.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBohfXsSsdOPehONm9_wTBZyCRwisgz9aJ3dCkffJnBa0VPZI5ACFzCTmoxct9mKGS2X4az5dhCXws75AREB4coWJWosfJUBYQ8MO0WnxciXPxhmstxFRQWb8M3OKTBjAi2clCr6maFv4/s320/IMG_2802.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Software loaded, everything is calibrated....</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
I purchased a 17 inch by 17 inch piece of aluminum plate from my local metal supplier. Once the piece was clamped in and the CNC machine was calibrated, it was time to sit back and watch it work.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEYFBHROJ7QmTMrk9866dQYk43Pl1ZtKQW4Q9hlfopMZFnMR8anAUR4zRvVoEFxfn_foWnqjw9ogYW0kMN7sgZHggJJrpvfusa1nzqj8Yzt4wAU6gtee0gK7EbhSL63Jo79ZTmo6_QOj8/s1600/IMG_2804.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOCR-QxO3_H0Kni5zHqVotNYMGODyL8Ieknwnyj9gy-H-uk7dDwZhdd-PdVgJCPQXi87yb9DGLvz96IzCD-oRGJpiJTMZNwmrHY3y8Y-cPlcLU2MRzeF7cjy9ds9qHNIWCLVa1jbmGtMo/s1600/IMG_2797.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOCR-QxO3_H0Kni5zHqVotNYMGODyL8Ieknwnyj9gy-H-uk7dDwZhdd-PdVgJCPQXi87yb9DGLvz96IzCD-oRGJpiJTMZNwmrHY3y8Y-cPlcLU2MRzeF7cjy9ds9qHNIWCLVa1jbmGtMo/s320/IMG_2797.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPtzOv7cIQy_YbgkZU01-C4Gx37B3Kqa5PnbSqITE-Sb0HJxejNhmaR7C6FgwtCms4JqA6N5q9mo63MayUo8EIlPr90C29AuofVgeTCaSjZse0Qt_2otQ8qf5j2QQX4xsOT5N4nPkvE3E/s1600/IMG_2804.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPtzOv7cIQy_YbgkZU01-C4Gx37B3Kqa5PnbSqITE-Sb0HJxejNhmaR7C6FgwtCms4JqA6N5q9mo63MayUo8EIlPr90C29AuofVgeTCaSjZse0Qt_2otQ8qf5j2QQX4xsOT5N4nPkvE3E/s320/IMG_2804.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<br />
And watch, we did. Since our CNC machine can only use one tool at a time, it did the entire piece with its 12mm cutting bit. More advanced machines could change tools to remove move material with larger bits, getting the job done much quicker. However, for us hobbyists, this works just fine despite taking a lot longer.<br />
<br />
Specifically, this took 8 hours and 41 minutes to cut! Then, another hour or so to remove all the tabs that hold many pieces in place until completed.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7RX1Z9MZhiWKMV_LDfM3sDEfMcjWVG3IADzjCW3Vk-Ncx7rinSuSXBuToJmIBUquUfcYa5CgrNxCMjCKVrZLrpirQKsdMF57Pzy0jV0-fcE1i1nxFK6HshuiWm6o1-jozroaVnDR8trI/s1600/IMG_2808.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7RX1Z9MZhiWKMV_LDfM3sDEfMcjWVG3IADzjCW3Vk-Ncx7rinSuSXBuToJmIBUquUfcYa5CgrNxCMjCKVrZLrpirQKsdMF57Pzy0jV0-fcE1i1nxFK6HshuiWm6o1-jozroaVnDR8trI/s320/IMG_2808.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">8 hours and 41 minutes later!</td></tr>
</tbody></table>
Once all the pieces that were no longer needed were removed, you can see how neat this part looks!<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqMyY_oMIiy2GYCre2Td8lHL-Cl7AWQat3vJErCruyzW8tT3dPplM1vwpJ1EYiZkEpbRmpaimzICnc4oBrCD3K_b7k_pWMhtDAOh_p9aPdKtrjcJdeW4zk0vYNVAgbXFMfYaw3Ce_rUeI/s1600/IMG_2809.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqMyY_oMIiy2GYCre2Td8lHL-Cl7AWQat3vJErCruyzW8tT3dPplM1vwpJ1EYiZkEpbRmpaimzICnc4oBrCD3K_b7k_pWMhtDAOh_p9aPdKtrjcJdeW4zk0vYNVAgbXFMfYaw3Ce_rUeI/s320/IMG_2809.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
The original metal plate weighed just over 6 pounds. After all the excess material was removed, the dome plate weighs 1.87 pounds.<br />
<br />
To remove all the metal scratches and lines left from the cutting bit, I had a friend bead-blast it.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhj-wIazUJIjyK1eEECEltC-aPigF_SKp6ibjFPRsinWhfScJNq03Akss1K06Yb16kAbzgPRYqdxSbSUWhuRDonaNYZR4GDa_iT2Vg5Q3yqBRm7EDL3jgmC5bY_qvUrQh77ewEVXGxhs4/s1600/IMG_2812.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhj-wIazUJIjyK1eEECEltC-aPigF_SKp6ibjFPRsinWhfScJNq03Akss1K06Yb16kAbzgPRYqdxSbSUWhuRDonaNYZR4GDa_iT2Vg5Q3yqBRm7EDL3jgmC5bY_qvUrQh77ewEVXGxhs4/s320/IMG_2812.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
To protect the finish, we clear coat the dome plate...<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEJmHjEJSfZfiLN77uO7xZV6Yb0FYEmq1iHgR_5FcVLyw2Poi_7hMGQxE7D1_fA_a50slcsefB0pujLSgIzrnENuMb09t4MAYqJMMa7_wLoX3nx4JlSOntPBNrpd3khJiIgQjb52y5zhw/s1600/IMG_2813.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEJmHjEJSfZfiLN77uO7xZV6Yb0FYEmq1iHgR_5FcVLyw2Poi_7hMGQxE7D1_fA_a50slcsefB0pujLSgIzrnENuMb09t4MAYqJMMa7_wLoX3nx4JlSOntPBNrpd3khJiIgQjb52y5zhw/s320/IMG_2813.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_xlr4qfv4iA_U6i3X2q0HruBfIzkhA38gLoKPQVBzVybn1-4ecDq3P-CcA_yO1oTkfJM_NqyDekD7ho3TK9DpfmP-OX-ZxiUrbwgC9awsgP4LHulLA8S6f34lfhty8EmD_nA3eL1epYE/s1600/IMG_2816.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_xlr4qfv4iA_U6i3X2q0HruBfIzkhA38gLoKPQVBzVybn1-4ecDq3P-CcA_yO1oTkfJM_NqyDekD7ho3TK9DpfmP-OX-ZxiUrbwgC9awsgP4LHulLA8S6f34lfhty8EmD_nA3eL1epYE/s320/IMG_2816.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5DOdakD4FZ7VgWo807rAddLWtyfsnLdkjYEwAPI4UclBtQHWBJe4RN9anpvM-4ZiWFnqIoSms830EwLv1oz48juTNdXcF0RFUQ3Ww8ajy5PdS1R3A5JhdY5R2FKD01vz1DeqIqMFKM68/s1600/IMG_2814.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5DOdakD4FZ7VgWo807rAddLWtyfsnLdkjYEwAPI4UclBtQHWBJe4RN9anpvM-4ZiWFnqIoSms830EwLv1oz48juTNdXcF0RFUQ3Ww8ajy5PdS1R3A5JhdY5R2FKD01vz1DeqIqMFKM68/s320/IMG_2814.jpg" width="320" /></a></div>
<br />
<br />
<br />
Granted, the only time people will see this part is if R2's dome is off. But, it was a great challenge to see if the CNC machine could make this piece!<br />
<br />
<br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-38807418692820205442013-03-03T21:37:00.000-05:002013-03-03T21:37:07.768-05:00What's new so far in 2013Over the past few months, I have been making R2-D2 parts for myself and other builders. Side Vents and the Data Panels took up a lot of time but it was a lot of fun. Working with my machinist friend, Fred, I've learned a great deal about working with aluminum, using a CNC machine and more. After years of building with hacksaws, Dremels and so on, its fantastic to learn how to use bigger and better tools!<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjik9inmkLjDZ0iCHizSRX7yGus-rl4eerZEITn5cGCxB8fn_v1wz9MaHgyQKN_UC0wTTPXGIsnuSmS7nzGgSXmiu_yBK8H9x6Npmdyyf84Fg59lP0tPZsIO2EsZ42qqS224bz67qaX_Js/s1600/IMG_2528.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjik9inmkLjDZ0iCHizSRX7yGus-rl4eerZEITn5cGCxB8fn_v1wz9MaHgyQKN_UC0wTTPXGIsnuSmS7nzGgSXmiu_yBK8H9x6Npmdyyf84Fg59lP0tPZsIO2EsZ42qqS224bz67qaX_Js/s320/IMG_2528.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">CNC machine cutting a Side Vent from 5052 aluminum</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGrH6dhcPg4BwKPdx9wQxwtjKCzaHwFwt5OL3pDeyzuJs9aVciKTvUVBYG_7zIvHR-wtFsA0C2WVrgplcTSNEQNiVw_3-OF1FYSMGbWiGSpN7P49CYS0Sg7k8XWtb8G0nPk-8O_LPzyXI/s1600/IMG_2677.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGrH6dhcPg4BwKPdx9wQxwtjKCzaHwFwt5OL3pDeyzuJs9aVciKTvUVBYG_7zIvHR-wtFsA0C2WVrgplcTSNEQNiVw_3-OF1FYSMGbWiGSpN7P49CYS0Sg7k8XWtb8G0nPk-8O_LPzyXI/s320/IMG_2677.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Making Data Panels</td></tr>
</tbody></table>
With my first R2-D2 functioning fine, I wanted to get back into getting the second one built. Recall that the second one is going to be my "uber" or "ultimate" R2-D2. Basically taking everything I learned building the first and making this one. Once completed, the first R2-D2 will have its blue parts painted pink, giving me a "girl" R2 for patient visitors.<br />
<br />
Over the past few days, with the assistance of my friend, we've installed the Data Port into the frame and made a surround piece that wraps behind the CPU Arm. Back in December we also got the CPU Arm mounted and actuated.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-fBZzaVWkFs91bzNettAXzm1L2sNpPj5eB_IORLYjId5FbZedTHjzFVBJUTNNxKnLoLlW76lM18eS5eww5tMU5IasSHpbSUkLk5Ow3qTSIznZiDPMNpD1oPObl-IAJorFWHjQBMRVYbg/s1600/IMG_2780.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-fBZzaVWkFs91bzNettAXzm1L2sNpPj5eB_IORLYjId5FbZedTHjzFVBJUTNNxKnLoLlW76lM18eS5eww5tMU5IasSHpbSUkLk5Ow3qTSIznZiDPMNpD1oPObl-IAJorFWHjQBMRVYbg/s320/IMG_2780.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Data Panel installed into the frame.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjon-7G9QClJ9g4XsjIDk03dKV24zyL4Z5rR38tK1TZuH-fKkVBd5sO8WeYkRHBPTIemfui0P0TvR8g_2SCcqWhVSQ4zLBDrMosEQfKMUByQxsOb9wM92bzJ-r5TGfgL8P4cdc0wgLMwfk/s1600/IMG_2782.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjon-7G9QClJ9g4XsjIDk03dKV24zyL4Z5rR38tK1TZuH-fKkVBd5sO8WeYkRHBPTIemfui0P0TvR8g_2SCcqWhVSQ4zLBDrMosEQfKMUByQxsOb9wM92bzJ-r5TGfgL8P4cdc0wgLMwfk/s320/IMG_2782.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Bottom part of the CPU Arm enclosure</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimM_WFGEgTi9A5TPk2G7MN5JikY3oAZLujnsZRPkZewnib9xkBlyZg_3LCtOov3ueMb813wCaD_DMlET0ILEAcbXG3uHw1GxWn_WCWg0tPnW1DBJj-CGS76YA6LnWCS3K_9_194zJru4s/s1600/IMG_2784.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimM_WFGEgTi9A5TPk2G7MN5JikY3oAZLujnsZRPkZewnib9xkBlyZg_3LCtOov3ueMb813wCaD_DMlET0ILEAcbXG3uHw1GxWn_WCWg0tPnW1DBJj-CGS76YA6LnWCS3K_9_194zJru4s/s320/IMG_2784.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Gently peeling the protective plastic layer from the aluminum to glue a rubber stopper.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwFLReWwqoNxXetUMVTImLKUw45u8LYSqJWsCSyjnCoOxybnmhJQxUaVTYCaeQ1BGUnrgIpvoKFCi-MMomNh6oWErpedqPO8zI7NZ4TO5j07qf7biMzPxiPkYqMTwgJ_8vp9zV2VPoGfM/s1600/IMG_2785.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwFLReWwqoNxXetUMVTImLKUw45u8LYSqJWsCSyjnCoOxybnmhJQxUaVTYCaeQ1BGUnrgIpvoKFCi-MMomNh6oWErpedqPO8zI7NZ4TO5j07qf7biMzPxiPkYqMTwgJ_8vp9zV2VPoGfM/s320/IMG_2785.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Surround enclosure installed</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-Kvdk8x_gg-6WjP0XXxVV4pFobtLFoL87m6F8d11DrCWav-x7uG4M2WmnIsKKhBd1dQExP4rNLkT5iNW5CSoK_10TfH0VhVQ62SrfIypXqF9KUzZtKTOAvbkwM20miZ1pPLL0OP3boKE/s1600/IMG_2787.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-Kvdk8x_gg-6WjP0XXxVV4pFobtLFoL87m6F8d11DrCWav-x7uG4M2WmnIsKKhBd1dQExP4rNLkT5iNW5CSoK_10TfH0VhVQ62SrfIypXqF9KUzZtKTOAvbkwM20miZ1pPLL0OP3boKE/s320/IMG_2787.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Looks great with the skin on. </td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin2hbwAW0pJVQIrWUJO0Jpw2FiyOfkSMZc_LUgF3lwXLLfwCJzMrT4Gp-Z48cG5ssng-6NJ1OfnN7i9Ah8JvtgRVztVqAzF9hyphenhyphenWVoHoLWuuqYoNU8IHEHaTvjVFPuBMdf0U9mRXWpDgYQ/s1600/IMG_2791.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin2hbwAW0pJVQIrWUJO0Jpw2FiyOfkSMZc_LUgF3lwXLLfwCJzMrT4Gp-Z48cG5ssng-6NJ1OfnN7i9Ah8JvtgRVztVqAzF9hyphenhyphenWVoHoLWuuqYoNU8IHEHaTvjVFPuBMdf0U9mRXWpDgYQ/s320/IMG_2791.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Rubber stopper prevent damage to the CPU Arm tip</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvDN3_cqelq7H877PJ_zMDJjtS6AaluvvvSH5K4kfkH2hHNrqJI939ImE2s4hyphenhyphenHM40aqA4bq49L1k5sarLC59TL20C5VtfgFymmJ0Pe0jDzswAPvNg4Y3a2fo6IKNKwPQV4kteA2QThTI/s1600/IMG_2793.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvDN3_cqelq7H877PJ_zMDJjtS6AaluvvvSH5K4kfkH2hHNrqJI939ImE2s4hyphenhyphenHM40aqA4bq49L1k5sarLC59TL20C5VtfgFymmJ0Pe0jDzswAPvNg4Y3a2fo6IKNKwPQV4kteA2QThTI/s320/IMG_2793.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back view of the surround</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
The CPU Arm assembly we made required some trimming of the metal shaft to fit the door opening. Then my friend came up with an ingenious way to mounting it all into the frame.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEPpx92-iRyk1YdQnFckl4_rRFtHw8e8heZhjC7HNofQ-Uf0K0FfjULa-kTIgkfbI8aMy9bkPGYhyphenhyphen2sYTzkmS7B4HrtyyX95Jk7lJcv35M7r_G24LD5NIqInK5KTYGKSCbQevGYsVX3Uo/s1600/IMG_2364.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEPpx92-iRyk1YdQnFckl4_rRFtHw8e8heZhjC7HNofQ-Uf0K0FfjULa-kTIgkfbI8aMy9bkPGYhyphenhyphen2sYTzkmS7B4HrtyyX95Jk7lJcv35M7r_G24LD5NIqInK5KTYGKSCbQevGYsVX3Uo/s320/IMG_2364.JPG" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">We had to take apart the metal CPU Arm and internal linkages to properly size them to fit the door opening. We then fabricated an adapter to thread from the L16 Firgelli Actuator and the threading of the CPU Arm tip</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjU57w00f8N5QvPHgx8mC4eXZoQSLc8EMOkaLlGe36LFLeY2YQBuV3fB8tDAlLix9OJqk4X6rpnw0B3mdslxGCCDevjFzmOSUL0Xw7mbpZf2byWbpnZWDozdcDPEonozHKf_pcAn_Ng3g/s1600/IMG_2366.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjU57w00f8N5QvPHgx8mC4eXZoQSLc8EMOkaLlGe36LFLeY2YQBuV3fB8tDAlLix9OJqk4X6rpnw0B3mdslxGCCDevjFzmOSUL0Xw7mbpZf2byWbpnZWDozdcDPEonozHKf_pcAn_Ng3g/s320/IMG_2366.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The inside of the metal CPU Arm was filed to fit actuator inside, then we came up with a way to secure it inside.</td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<br />
<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz38t1pNPJKeQB5uWP-j8uMpVrAxiBWIYOUb1Ek3PX6Ryte9lZ-52yr8q0VWTDJcc6Q_fxGWNifAeq8bvqE45e-eBBJrE9TkQ_Nb0x9HbMqFqUiCXTYfE97zficUxniqY3GMEiAuFAHPM/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz38t1pNPJKeQB5uWP-j8uMpVrAxiBWIYOUb1Ek3PX6Ryte9lZ-52yr8q0VWTDJcc6Q_fxGWNifAeq8bvqE45e-eBBJrE9TkQ_Nb0x9HbMqFqUiCXTYfE97zficUxniqY3GMEiAuFAHPM/s320/BlogPic02.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Servo on the left doesn't have enough torque but the one on the left will. The CPM Arm bracket is ready to be installed</td></tr>
</tbody></table>
<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgk0b_o6KaC3qyusz3TbjVj90_3Vv8sd7lZfEOYSjZPyBwLpyE8ww6Ru2Svo8b5dGQhTnFEWBPuhlbQkJO5DrtxzB1yek5q82dCEUV0RaAwCbn0Rhq5wTqphm7Cz3E_kdFV4efTjQYmro/s1600/BlogPic04.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgk0b_o6KaC3qyusz3TbjVj90_3Vv8sd7lZfEOYSjZPyBwLpyE8ww6Ru2Svo8b5dGQhTnFEWBPuhlbQkJO5DrtxzB1yek5q82dCEUV0RaAwCbn0Rhq5wTqphm7Cz3E_kdFV4efTjQYmro/s320/BlogPic04.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The CPU Arm hangs directly over the frame ring, so it won't be in the way of the skins nor the mechanisms behind it. You can see the two levers, one of which the large servo will attach to.</td></tr>
</tbody></table>
<br />
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaIZPpuf5Ky7ODuoAHpmXz26UzrTlggW7cG37Zwu097s-QNpvgvV_oVD1F9pgbr8W3JUDAac4ZhTxla50TgYv75uaW7FkEuCLSQnY_z7b9EOcKqVB6ZZxd1043DAa_VSwH_vJqtSoL8yA/s1600/BlogPic09.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaIZPpuf5Ky7ODuoAHpmXz26UzrTlggW7cG37Zwu097s-QNpvgvV_oVD1F9pgbr8W3JUDAac4ZhTxla50TgYv75uaW7FkEuCLSQnY_z7b9EOcKqVB6ZZxd1043DAa_VSwH_vJqtSoL8yA/s320/BlogPic09.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Close up</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2Zbjl18b7thUax6_5hxVd4zj6fE1FcyPwD9b8EwYox5GG_MvEcShh6c5ZcTo-Uk_Uwvno51fLltEY24nf1ISE7RtMseU9K0cenB2HkizG2vMwpK37phPP4njYLltkHvI7hyuICzLyTZE/s1600/BlogPic05.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2Zbjl18b7thUax6_5hxVd4zj6fE1FcyPwD9b8EwYox5GG_MvEcShh6c5ZcTo-Uk_Uwvno51fLltEY24nf1ISE7RtMseU9K0cenB2HkizG2vMwpK37phPP4njYLltkHvI7hyuICzLyTZE/s320/BlogPic05.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Arm pivoted out</td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRkprw0rf3x06QIUoHZ_JevmRcGQTVwwv4PRw8RgPQuYDSjF2SJ-hNtqS235ytsQwEQRFLiQ7QnxxUZw0HAqRafG_VpMBJtA4bk27fcrJAKj58zSOtqE3f1xNdMkgOSbp8HeJbla954OE/s1600/BlogPic06.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRkprw0rf3x06QIUoHZ_JevmRcGQTVwwv4PRw8RgPQuYDSjF2SJ-hNtqS235ytsQwEQRFLiQ7QnxxUZw0HAqRafG_VpMBJtA4bk27fcrJAKj58zSOtqE3f1xNdMkgOSbp8HeJbla954OE/s320/BlogPic06.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drilling and tapping two holes into the frame rod to attach the large servo to.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDcpCQIm6oM65pIHqBUuym4oFbu-4tC5M-N5DaQA5x9f9cPK6WqChX1nDx1bhtCxm7gKodRH-9Z65EyJpKi5RX0MCqkYyOXYAs1hlsNYyDGNCI3fL9FwjkUATCJb5y24PmyOrJjprqQYk/s1600/BlogPic12.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDcpCQIm6oM65pIHqBUuym4oFbu-4tC5M-N5DaQA5x9f9cPK6WqChX1nDx1bhtCxm7gKodRH-9Z65EyJpKi5RX0MCqkYyOXYAs1hlsNYyDGNCI3fL9FwjkUATCJb5y24PmyOrJjprqQYk/s320/BlogPic12.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Servo installed, linkage from CPU Arm lever attached. Now to attack to the servo</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2SA6vXB4GMytIolPQ473RcTWsGXrWnJskkSHMTklvVqSYVAsJ_DkK9y1n8UM4Ob1ugzgh2jZdLUzQNThVjOBvj03p0qOYd4ekQm6ZkaotLh8PEP6YRODdHxlAEUb2cUpQ-6DquR3TdCE/s1600/BlogPic13.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2SA6vXB4GMytIolPQ473RcTWsGXrWnJskkSHMTklvVqSYVAsJ_DkK9y1n8UM4Ob1ugzgh2jZdLUzQNThVjOBvj03p0qOYd4ekQm6ZkaotLh8PEP6YRODdHxlAEUb2cUpQ-6DquR3TdCE/s320/BlogPic13.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Testing it out, plenty of power to lift the CPU arm...and the actuator pushes the probe out</td></tr>
</tbody></table>
<br />
<br />
<br />
<br />Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-51274398269902509752012-11-16T22:19:00.000-05:002012-11-16T22:19:17.323-05:00Aluminum half moons and dome panels ready!<span style="font-family: Verdana, sans-serif;">Today the aluminum half moons arrived, which are the large details pieces that fit on the feet.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">In an effort to reduce weight, I was going to use resin ones but had some concerns how well they would hold up in the center foot. In there, the half moons are how the caster mounting plate stays attached. Drilling and tapping resin pieces isn't nearly as solid as aluminum.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">As it turns out, one of the R2 Builders had just done a part rum of the aluminum half moons and had extras available. Even better, these are the "diet" version, where additional material has been cut away to lighten the part.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAG40517mbJ-BwZrwh4IDbBVnGOAMqUAbGRRxA1crVNCnOrM5I2Nase2bSKaPk_YLuG5HnZ9ViLT1WuXaKjvNS8bcIVTymTarajw92PAEuM4m_QgtHCe7mqPByUpgnt8Oie0MPFOlKzgw/s1600/BlogPic02.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAG40517mbJ-BwZrwh4IDbBVnGOAMqUAbGRRxA1crVNCnOrM5I2Nase2bSKaPk_YLuG5HnZ9ViLT1WuXaKjvNS8bcIVTymTarajw92PAEuM4m_QgtHCe7mqPByUpgnt8Oie0MPFOlKzgw/s320/BlogPic02.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Note the back of the piece has had a lot of excess material removed to reduce weight</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">The temperature in my part of Maine was 29F so the days of painting outside are long gone. So, I turned on the heater and then set up some proper ventilation to prime and paint them...</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYbjpCMkhY4Bas7qWdFE8WTESLZ_8vbhfIZJpCXNKpTnwHNX6CsJQVPWihnqlAKWgonlUtEPfOCevdbwlUP2PhtHBj-BNUnGyTvWkjsCswwmDN4J1efWuPRlacvcCl1hpOq_0Dx0tn_RY/s1600/BlogPic03.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYbjpCMkhY4Bas7qWdFE8WTESLZ_8vbhfIZJpCXNKpTnwHNX6CsJQVPWihnqlAKWgonlUtEPfOCevdbwlUP2PhtHBj-BNUnGyTvWkjsCswwmDN4J1efWuPRlacvcCl1hpOq_0Dx0tn_RY/s320/BlogPic03.JPG" width="239" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2e5SroVVz-JaQ3e1HGk0ELTgQvC-VR7c9jiCeRDSMn6p1NQUvLs1HGmm2i6FnZESy1QNYCczH6wUBnntQLVEC79ZYh9kvjiqWgNNzx39P71DQ94NOeugEAYW62oV-7UGtMtOzciPTfEM/s1600/BlogPic04.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2e5SroVVz-JaQ3e1HGk0ELTgQvC-VR7c9jiCeRDSMn6p1NQUvLs1HGmm2i6FnZESy1QNYCczH6wUBnntQLVEC79ZYh9kvjiqWgNNzx39P71DQ94NOeugEAYW62oV-7UGtMtOzciPTfEM/s320/BlogPic04.JPG" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Once the paint fumes had been vented outside, I was able to jump back to work on the dome panels which all needed some polishing.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjejw0bGSKT8NNL3wy8tzGRgTduHqPTEm07Q7lXL60jboVJ_xEtp03KU-bkBiCSObDvemL_FT5fprVb2bcb0vDagqC6IaliOOa4gz-sSFiHG01yPNCPl3KntUOtH17Elgfp1jnnHed4B8Y/s1600/BlogPic06.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjejw0bGSKT8NNL3wy8tzGRgTduHqPTEm07Q7lXL60jboVJ_xEtp03KU-bkBiCSObDvemL_FT5fprVb2bcb0vDagqC6IaliOOa4gz-sSFiHG01yPNCPl3KntUOtH17Elgfp1jnnHed4B8Y/s400/BlogPic06.JPG" width="298" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Despite taking a LOT of pictures, the shininess made for a lot of out of focus pics! </td></tr>
</tbody></table>
<br />
<span style="font-family: Verdana, sans-serif;">Tomorrow I'll work on testing out the new airbrush and if that goes well, prep and work on getting the panels that get blue paint done!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<span style="font-family: Verdana, sans-serif;"><br /></span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-24436398347073592122012-11-13T23:04:00.000-05:002012-11-13T23:17:26.358-05:00More dome panel work and CPU Arm arrives!<span style="font-family: Verdana,sans-serif;">Tonight I did some more sanding on the
dome panels, finishing up using 1000 grit and 1500 grit. Now we're
starting to see if I should polish with the Mother's polish or not.</span><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixS3cUEjV4t2jdHHeg-nGYFnU6DCD7ogf6NjIWLpiA-6pvUXJI16l2n9IdBLa6bJkramR0HsQNtqRwcUSBkvkUzFT95xUJWjy7r6swF3MVDnt_yQ0dFUmznZZmpUdZc8A_fbN9886ymXQ/s1600/BlogPic12.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixS3cUEjV4t2jdHHeg-nGYFnU6DCD7ogf6NjIWLpiA-6pvUXJI16l2n9IdBLa6bJkramR0HsQNtqRwcUSBkvkUzFT95xUJWjy7r6swF3MVDnt_yQ0dFUmznZZmpUdZc8A_fbN9886ymXQ/s320/BlogPic12.jpg" width="239" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">These haven't been polished yet and I'm awful tempted to leave them as is....naaah</td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><br />
<br />
<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_dlNWVGA72gxyUad0XlCPBegwB-qofmdVC8MVtJNBZ3aidTNUKdgk335Q4xeZF7jzhFGuUIxNHNpaLmmqKSjkSVO8RVTXFkfYO2C8N8SA5SVWADy5yCZOV1GCIJG5llpf8ug5TMAXd_4/s1600/BlogPic11.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_dlNWVGA72gxyUad0XlCPBegwB-qofmdVC8MVtJNBZ3aidTNUKdgk335Q4xeZF7jzhFGuUIxNHNpaLmmqKSjkSVO8RVTXFkfYO2C8N8SA5SVWADy5yCZOV1GCIJG5llpf8ug5TMAXd_4/s320/BlogPic11.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">These I used the Mother's aluminum polish and drill-power buffer</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">Also, today the CPU Arm arrived, this one being made entirely of aluminum. Its going to be a bit of a challenge to motorize and actuate in and out of R2's panel opening....but I'm sure I can sort something out.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9nu4QYsNBW8On0UexeFU47rSJYvcAgaLHnk7JOrVXqDRlHBHegdlSrL7tcMsDo69oHxdVhWM6o497Mx3H67cu6Hd9QaLNEQsJOHK0IDlsadlQ_hJqBVqmxCLbJ3_UyDM_JIi65UXsjTM/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9nu4QYsNBW8On0UexeFU47rSJYvcAgaLHnk7JOrVXqDRlHBHegdlSrL7tcMsDo69oHxdVhWM6o497Mx3H67cu6Hd9QaLNEQsJOHK0IDlsadlQ_hJqBVqmxCLbJ3_UyDM_JIi65UXsjTM/s320/BlogPic02.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhax0tn-wxqPYre0pp-F51_A4xLHnkvq-4jHohgNHbiz73YFJppLpEOuK5UycrV22AjSV0KrrTvWoM72o2YMwfVivTWYsng1ZilHlisqc4Uigo_KxrdtiUVhc8iQojwTTRy7XgGp9oOaIo/s1600/BlogPic03.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhax0tn-wxqPYre0pp-F51_A4xLHnkvq-4jHohgNHbiz73YFJppLpEOuK5UycrV22AjSV0KrrTvWoM72o2YMwfVivTWYsng1ZilHlisqc4Uigo_KxrdtiUVhc8iQojwTTRy7XgGp9oOaIo/s320/BlogPic03.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRW3hiJ1emQShIUTekOmnn1OwJoXcujcMhAshZFx4Ry5aZQc18nupuk934csn0V36gXBod3zR-555wM0yPcz6Z-Qf_LeWaOV3VWZ6AoopnIg16j2jpHUMVNPvVLeD1MWomhwTIsbyeW1o/s1600/BlogPic07.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRW3hiJ1emQShIUTekOmnn1OwJoXcujcMhAshZFx4Ry5aZQc18nupuk934csn0V36gXBod3zR-555wM0yPcz6Z-Qf_LeWaOV3VWZ6AoopnIg16j2jpHUMVNPvVLeD1MWomhwTIsbyeW1o/s320/BlogPic07.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1DA_V4MtBZGXYg7Su2a-dtmmTIHp4IUhpNY3jr3w2V_dzBRABVEto4qaF7aF5KaehF8dCAVDTxkGbTjkyTlaRUdtkaRxpt4AzHzlmmlvN6WtkFiNAEIwF2n59YSWkOTGXa8yLD9Fc92Y/s1600/BlogPic09.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1DA_V4MtBZGXYg7Su2a-dtmmTIHp4IUhpNY3jr3w2V_dzBRABVEto4qaF7aF5KaehF8dCAVDTxkGbTjkyTlaRUdtkaRxpt4AzHzlmmlvN6WtkFiNAEIwF2n59YSWkOTGXa8yLD9Fc92Y/s320/BlogPic09.jpg" width="238" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">The previous R2-D2 has a resin-version of the CPU arm. This metal one mimics the one seen in the various scenes of the the original Star Wars: A New Hope film.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJTL0jxLMPFvpte1RgN_5FxGquEO0p64T03DjxEFtNd0deD1x4jp1Dqop6K4opOUihbWNkIOcsa_JSVsH_8LmRAj4taTz0QrjzcQG_ukcLloGdFuTNG3t68yQRjR3I5gSFhofPrHmtc7Q/s1600/Capture.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="168" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJTL0jxLMPFvpte1RgN_5FxGquEO0p64T03DjxEFtNd0deD1x4jp1Dqop6K4opOUihbWNkIOcsa_JSVsH_8LmRAj4taTz0QrjzcQG_ukcLloGdFuTNG3t68yQRjR3I5gSFhofPrHmtc7Q/s400/Capture.JPG" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Screen capture from R2-D2 plugging into a Death Star computer terminal</td></tr>
</tbody></table>
<br />
<span style="font-family: Verdana,sans-serif;">I'll have to slow-motion a few scenes to be sire of what gets painted where....but it looks promising!</span><br />
<br />
<br />Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-88984482121785662122012-11-12T22:11:00.001-05:002012-11-12T22:11:37.139-05:00We have Side Vents<span style="font-family: Verdana,sans-serif;">Over the weekend, my machinist friend was able to make me some aluminum side vents for my R2-D2s. These came out awesome, all I need to do is polish up the outer piece and paint the back piece blue.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeqhGwlAMtP2ydcRhx6cLrJ1IQfZZe0YLh_WA5llrmoZ0HB6Nueo9KWLnJEjIiAfi7ueC1DUPnf7t82CooAUjQFHGMOP8LunAN2DvOp19PPBRsEoQAmrsmMw0NTYWjNo9rLhn7FKEt3EY/s1600/BlogPic03.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeqhGwlAMtP2ydcRhx6cLrJ1IQfZZe0YLh_WA5llrmoZ0HB6Nueo9KWLnJEjIiAfi7ueC1DUPnf7t82CooAUjQFHGMOP8LunAN2DvOp19PPBRsEoQAmrsmMw0NTYWjNo9rLhn7FKEt3EY/s320/BlogPic03.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1fCol4nhDwwTYcrWlsbTKP7Q4w3x7IU5gR03RkQzyE2r6sRl8RwJqyJYkLeF8KeRpCRIOLIZFdSSSZwfppygnTVhBXv0pViDrh5K9g88nPYRcKhhpzLl5S0o_9BV9uh-BkiJR_Fze3T0/s1600/BlogPic01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1fCol4nhDwwTYcrWlsbTKP7Q4w3x7IU5gR03RkQzyE2r6sRl8RwJqyJYkLeF8KeRpCRIOLIZFdSSSZwfppygnTVhBXv0pViDrh5K9g88nPYRcKhhpzLl5S0o_9BV9uh-BkiJR_Fze3T0/s320/BlogPic01.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-dRsiVKoNRrq9K-NF2Oy8fXHWCyKF1R5xYwYnDnQ44mB-hauPQcMhU3TP46gOywc1gKDnQVQrjUBkkaCXZG56eRRkCdkPPOCDzFSoelLiL6G4R83_l5DDX53bOpU3gd8trlBqXVZ6b54/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-dRsiVKoNRrq9K-NF2Oy8fXHWCyKF1R5xYwYnDnQ44mB-hauPQcMhU3TP46gOywc1gKDnQVQrjUBkkaCXZG56eRRkCdkPPOCDzFSoelLiL6G4R83_l5DDX53bOpU3gd8trlBqXVZ6b54/s320/BlogPic02.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdSuCZcQJJ6IH27nuceLZij7NBLFjPJd0cLKjFVx7n6yBlHqrOdUyDIMWsO924LSFan3OcJZBhFadRwJaXSi_q8PxNhcSqS2LrEVdCiZ2Dc_2nTAcmlPCB-8Fmk1VZxn5q-Cia96BzDE4/s1600/BlogPic05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdSuCZcQJJ6IH27nuceLZij7NBLFjPJd0cLKjFVx7n6yBlHqrOdUyDIMWsO924LSFan3OcJZBhFadRwJaXSi_q8PxNhcSqS2LrEVdCiZ2Dc_2nTAcmlPCB-8Fmk1VZxn5q-Cia96BzDE4/s320/BlogPic05.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOafDcH2AInnLucZxU0i5wouw1CAcvZRrDLlFX1bWv_-MeYVqmLVk00HbdKnRdu58hFRJ_s917pQZhwtmq1i5dVZhes0yZp6LtCEwldBGNSt5ojSkIRMRLBTkU5wm2kzXQITC1iUpIu1g/s1600/BlogPic07.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOafDcH2AInnLucZxU0i5wouw1CAcvZRrDLlFX1bWv_-MeYVqmLVk00HbdKnRdu58hFRJ_s917pQZhwtmq1i5dVZhes0yZp6LtCEwldBGNSt5ojSkIRMRLBTkU5wm2kzXQITC1iUpIu1g/s320/BlogPic07.jpg" width="320" /></a></div>
<br />Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-3104852602585153432012-11-11T22:12:00.001-05:002012-11-11T22:12:22.602-05:00Dome panel sanding continues<span style="font-family: Verdana, sans-serif;">Well its slow work but I am still working on the dome panels</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">The mouse sander paper only goes up to 220 grit, so the rest is all by hand.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfbvkjsCtMBLalHQ0hNGQsNJrDgLEPVbDZx-ed6Tj8yrhxRkyd5n2rcsLAzec7X574cJj1lB-EOPaNUJh5IfRl2IHBkBg39wgEJEP9cIpkquOWp9Nw3sBzS5HDG-fO0a9eNvrR8qV5r5A/s1600/BlogPic01.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfbvkjsCtMBLalHQ0hNGQsNJrDgLEPVbDZx-ed6Tj8yrhxRkyd5n2rcsLAzec7X574cJj1lB-EOPaNUJh5IfRl2IHBkBg39wgEJEP9cIpkquOWp9Nw3sBzS5HDG-fO0a9eNvrR8qV5r5A/s320/BlogPic01.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">After sanding by hand with the 320 grit</td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<br />
<span style="font-family: Verdana, sans-serif;">Over Sunday I went from 320 grit, 400 grit, 600 grit and then 800 grit The pieces look really good. Next up is 1000, 1500 and 2000. I haven't been wet sanding this time around, less mess.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEillCNFMFKPaAkw5Q4Y7e3io94IQlmH1EJIVBUTm4GCf9T_g_eFRmOuSxeB3vYnH6mXxTZdEF_oukBKQM9pmVk1FeO8nOBfgHgLMM4yv7ebGiR5Ldz14GBZwNzCJXHBRtL2koSEde9BYlY/s1600/BlogPic03.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEillCNFMFKPaAkw5Q4Y7e3io94IQlmH1EJIVBUTm4GCf9T_g_eFRmOuSxeB3vYnH6mXxTZdEF_oukBKQM9pmVk1FeO8nOBfgHgLMM4yv7ebGiR5Ldz14GBZwNzCJXHBRtL2koSEde9BYlY/s320/BlogPic03.JPG" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij9i4C8LCdw4LRvXqW2PxF_ifCGtZW6shUA1SDbAN-gBitBxgGSgWnXeWrufDuEWV1TxTFyO0Ty9e-0PU5mrRkAjF11z24h9RYS3O62jQlRkIE4_kg8XTo5caQjKVHyxV9I5VtuQEUE7Q/s1600/BlogPic04.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij9i4C8LCdw4LRvXqW2PxF_ifCGtZW6shUA1SDbAN-gBitBxgGSgWnXeWrufDuEWV1TxTFyO0Ty9e-0PU5mrRkAjF11z24h9RYS3O62jQlRkIE4_kg8XTo5caQjKVHyxV9I5VtuQEUE7Q/s320/BlogPic04.JPG" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">I'm really looking forward to see how the Dykem Blue looks on these very polished pieces.</span><br />
<span style="font-family: Verdana, sans-serif;"> </span><br />
<br />
<br />Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-12657252335456442242012-11-08T21:50:00.001-05:002012-11-08T21:50:26.483-05:00Prepping dome panels and removing spin lines<span style="font-family: Verdana, sans-serif;">Tonight I dedicated some time to work on the dome panels again.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Earlier I had experimented on how much work it would take to get the panels to a fine polished finish. Since the Dykem Blue dye that will be airbrushed on is transparent, the spin lines would show thru otherwise.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Several of the panels had spin lines that 120 grit sandpaper couldn't tame down. So, I decided to do all of the panels with 60 grit sandpaper tonight. Over the next few days, I will work on bringing them closer to that shiny finish with increasing grit level sandpaper....120, 220, 320, 400, 600, 800, 1000, 1500, 2000 and then the Mother's aluminum polish applied with the drill-mounted polishing ball.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Here's how the pieces look now...</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQQs0ATcya5TgxD5EIdiel-Xs6bG7M1O5d-KZzCJRDZv9quP5Vh1D8stDkT50lG3c6agUUlRZ82JF7A25s8TqCHrxtDuuHq6rER7cbMRUBzHFJjY4dHPy0Ka0mEoeFpGNs0yqQfNcoeIU/s1600/BlogPic01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQQs0ATcya5TgxD5EIdiel-Xs6bG7M1O5d-KZzCJRDZv9quP5Vh1D8stDkT50lG3c6agUUlRZ82JF7A25s8TqCHrxtDuuHq6rER7cbMRUBzHFJjY4dHPy0Ka0mEoeFpGNs0yqQfNcoeIU/s320/BlogPic01.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiZlq7_2BlKdfj0Ygw35H6ezQt5_SyDjI6AxwteWfjXmAfDnu5O4mpAnkGnavE_kfk0cZAzUR7Jk9LALoi3qlOg0NoNl4CXiTD8Lz-Pup-cmI4sX9HGy5ybniL-0jKgSyJKof-wUHfGZQ/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiZlq7_2BlKdfj0Ygw35H6ezQt5_SyDjI6AxwteWfjXmAfDnu5O4mpAnkGnavE_kfk0cZAzUR7Jk9LALoi3qlOg0NoNl4CXiTD8Lz-Pup-cmI4sX9HGy5ybniL-0jKgSyJKof-wUHfGZQ/s320/BlogPic02.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyxaKMGFfY95zQz95BOmM_oMs4fCbx1xsteoVFqwHB59mNItKs1xQKaObKvymX54MWCXcoKC_bG03SudkS9AY-ayYAehA8lLWvTRg4M6Psfworwojx4MQ7SfMhKpmh_daY7cyzn6VtK2k/s1600/BlogPic04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyxaKMGFfY95zQz95BOmM_oMs4fCbx1xsteoVFqwHB59mNItKs1xQKaObKvymX54MWCXcoKC_bG03SudkS9AY-ayYAehA8lLWvTRg4M6Psfworwojx4MQ7SfMhKpmh_daY7cyzn6VtK2k/s320/BlogPic04.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Today I also replaced the used airbrush with a new one, a Testors model that should work just fine for spraying the Dykem blue!</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4TVA2cS-V9V7rOmG5-jqe64zcU9ocYRWsH9SQ8xYGtVU82rwrccAyUYe2R8oPJAGskr818Zzjew2AZ0Z8h9940qq8HIjDIKD0wAPpA_OL2-SgU_7B2i_u2AzOWx-2417Z46fH_OFMAs0/s1600/BlogPic05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4TVA2cS-V9V7rOmG5-jqe64zcU9ocYRWsH9SQ8xYGtVU82rwrccAyUYe2R8oPJAGskr818Zzjew2AZ0Z8h9940qq8HIjDIKD0wAPpA_OL2-SgU_7B2i_u2AzOWx-2417Z46fH_OFMAs0/s320/BlogPic05.jpg" width="320" /></a></div>
<span style="font-family: Verdana, sans-serif;"> </span><br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-4818738477385284722012-10-20T23:21:00.000-04:002012-10-20T23:21:34.162-04:00Let the paint work begin!<span style="font-family: Verdana, sans-serif;">Today was the day to begin paint a few pieces and see how things went.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">I already had a small stack of resin and metal pieces that are ready to go...</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTVII2WjiCggY4W-AMSRg7LRRJYmpis3YErRUuBMvPrKSxxfUPmf1az-5YEjbVkwuXfobV03mo5Q6EXAdBf-WULj5GyTfEh2NpmxvRAbo6PDGhifW7sPWxJoN8TWKE2QxXDRkJJUiwBp4/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTVII2WjiCggY4W-AMSRg7LRRJYmpis3YErRUuBMvPrKSxxfUPmf1az-5YEjbVkwuXfobV03mo5Q6EXAdBf-WULj5GyTfEh2NpmxvRAbo6PDGhifW7sPWxJoN8TWKE2QxXDRkJJUiwBp4/s320/BlogPic02.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Coin slots and power couplers</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQIvs2_7HCF1_41mlymvCYagCs7jSq5MTFp1jeunLmtRXFK0A_80OsQa4NBemmNFV-B9Ju1NwWgIIa188sURydOAB20J5r3YVi59zwUZEH5xcd2R7cUot0Jr4fgrx0I1qLYaIb5pyER7A/s1600/BlogPic03.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQIvs2_7HCF1_41mlymvCYagCs7jSq5MTFp1jeunLmtRXFK0A_80OsQa4NBemmNFV-B9Ju1NwWgIIa188sURydOAB20J5r3YVi59zwUZEH5xcd2R7cUot0Jr4fgrx0I1qLYaIb5pyER7A/s320/BlogPic03.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Resin booster rocket covers, aluminum utility arms, large data port and the vent surround piece</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"> I decided to dismantle the power couplers and used painters tape to protect the areas that will not get painted.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid0_4uyNGTxl4CtymGzhm6qXgcLy6-fbK21x_OW3NlqKcb9F1aBXsjaVU0FpTUbUP4qnRAchJt_jy5_e-ISE6xmRpJWDtlOyYpVuxE5zZmyNIdJn7nvNkamxo95p1dO_a34VVycN1re2w/s1600/BlogPic04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid0_4uyNGTxl4CtymGzhm6qXgcLy6-fbK21x_OW3NlqKcb9F1aBXsjaVU0FpTUbUP4qnRAchJt_jy5_e-ISE6xmRpJWDtlOyYpVuxE5zZmyNIdJn7nvNkamxo95p1dO_a34VVycN1re2w/s320/BlogPic04.jpg" width="320" /></a></div>
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Here is how the parts looked after being painted.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig3S5GLg_eZpELLXkIa2rBFd52sOOwjVjGamfKoeUcbC6ZvTlgmgUdcDAfaXkLqNuKeJ1nqkCyYZQlv4c6MkDsw4hih7ONmZFYWxLE6k4AWRo_6dlJwYImrdTJMUOlYxvTHJEiMnlxNsI/s1600/BlogPic05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig3S5GLg_eZpELLXkIa2rBFd52sOOwjVjGamfKoeUcbC6ZvTlgmgUdcDAfaXkLqNuKeJ1nqkCyYZQlv4c6MkDsw4hih7ONmZFYWxLE6k4AWRo_6dlJwYImrdTJMUOlYxvTHJEiMnlxNsI/s320/BlogPic05.jpg" width="320" /></a></div>
<br />
<span style="font-family: Verdana, sans-serif;">I had problems with my airbrush maintaining a normal flow of Dykem. I really need a new one...but I had been able to make it work up til now. As a result of that, some parts will need to be wiped down with Dykem Cleaner and do again...as in the case of the utility arms would up with some heavy spots...</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbXNe1VhsiDO6Q1HhyPq3wqWnOF1zjT-e_bu11M1dbNC3oc1f3G7YW8SCakQuydML3L6Fdp_YFLR1Jk77IihKzwMNaTUKgcO-bLNnpuINYEsZsCIfL-RI-1T3U61IMhIa6IlwwRAk_nv0/s1600/BlogPic07.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbXNe1VhsiDO6Q1HhyPq3wqWnOF1zjT-e_bu11M1dbNC3oc1f3G7YW8SCakQuydML3L6Fdp_YFLR1Jk77IihKzwMNaTUKgcO-bLNnpuINYEsZsCIfL-RI-1T3U61IMhIa6IlwwRAk_nv0/s320/BlogPic07.jpg" width="320" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">The power couplers came out alright. The tape removal managed to remove to peel off a bit of blue paint here and there....but still a good result overall.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidhHn3zKvMYA_5uxMgHKPehv0fRDCfPOB7I_Air7TwpB6TTuKiYgMSOlUACDTq_NUswpXik0Z0iimwU35YxbLgejP0TGT-HTlnrS9zhpxYHA6Fyig08MG95pQnCmLyuzXshjIQ4XwnNk8/s1600/BlogPic08.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidhHn3zKvMYA_5uxMgHKPehv0fRDCfPOB7I_Air7TwpB6TTuKiYgMSOlUACDTq_NUswpXik0Z0iimwU35YxbLgejP0TGT-HTlnrS9zhpxYHA6Fyig08MG95pQnCmLyuzXshjIQ4XwnNk8/s320/BlogPic08.jpg" width="320" /></a></div>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsj8EM3KqRcvOXouV8ocPyW4LswwGXItUNIWCWFRMjPRO6E0lUlyXGhU6nO-fWXokNiZy9Zofyhyphenhyphene-3ndRD-RLz5jskI4jOsdEu-dJU4WvOKRpZOENwNHOtKwIVxT6jZi3WTyJUzNTxwY/s1600/BlogPic10.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsj8EM3KqRcvOXouV8ocPyW4LswwGXItUNIWCWFRMjPRO6E0lUlyXGhU6nO-fWXokNiZy9Zofyhyphenhyphene-3ndRD-RLz5jskI4jOsdEu-dJU4WvOKRpZOENwNHOtKwIVxT6jZi3WTyJUzNTxwY/s320/BlogPic10.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">With camera flash on</td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;">The coin slots probably came out the best. After using the Dremel sanding wheel flap to remove paint from the front of the slots, I used some 400 grit sandpaper to clean it up even more...</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHFugkMTSv6tgQkRz__nw8WEeYDu4flSu2bXpZhcNSDhosXZoKTagwWla4llualnS-_DSGQUE1pjgXBNbH3Kt4sX62_C3BPJr-Cwy_YJkwdLhL1-yqBNOtTusWJ5wDBSBG4-g2HVVnSfQ/s1600/BlogPic06.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHFugkMTSv6tgQkRz__nw8WEeYDu4flSu2bXpZhcNSDhosXZoKTagwWla4llualnS-_DSGQUE1pjgXBNbH3Kt4sX62_C3BPJr-Cwy_YJkwdLhL1-yqBNOtTusWJ5wDBSBG4-g2HVVnSfQ/s320/BlogPic06.jpg" width="320" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">So a few parts got done today. Once I have the airbrush resolved...or replaced, we'll get more painting done. In the mean time, I have plenty more pieces that need sanding and polishing!</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-15850370720472590752012-10-20T00:40:00.000-04:002012-10-20T00:40:44.155-04:00Working on a new R2-D2 Blue<span style="font-family: Verdana, sans-serif;">Over the past few weeks, I've been working on a new "blue" for the second R2-D2. Some of the R2 Builders have discovered that the original R2 from the 1977 movie used a blue metallic dye. Archival photos showed the crew re-applying additional coats of the Dykem Steel blue metal dye as it fades fairly quickly.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">What's phenomenal about the Dykem is how purple in hue the color is, despite being blue. You can really see it in R2's Radar Eye...</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPvHsE74qLSKDWsp6SJu1UIyPn8aNSsLLilziLx214sxbc5oaN_Oe0DYIz06HqTNmt64naeZbuf347gHj6gUdmZGHoVfJbjlLTHvW4dnEMjZqT2KxRJ9iSQ4b5EUMoOw5NROOpV8C9saQ/s1600/Capture2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPvHsE74qLSKDWsp6SJu1UIyPn8aNSsLLilziLx214sxbc5oaN_Oe0DYIz06HqTNmt64naeZbuf347gHj6gUdmZGHoVfJbjlLTHvW4dnEMjZqT2KxRJ9iSQ4b5EUMoOw5NROOpV8C9saQ/s320/Capture2.JPG" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">My first R2 uses what is called the "Krider" formula, for the gent who came up with a really close match to the blue-purple hue that is R2-D2 Blue. It uses a base coat of a Rustoleum metallic purple, then a coat of Duplicolor Anodized Blue, followed by several coats of clear coat. The problem is that Rustoleum metallic purple is no longer available and efforts to duplicate or mimic it have been problematic. The subsequent R2 units in the movies used House of Kolor paints which, although pricey, is available.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Seeing the results from the samples other builders shared looked really good. The Dykem product is available locally for under $10, requiring an airbrush for best results. As the builders tested it out more, we found that adding a UV Clearcoat helps preserve the color. However, it was a little too purple in most lighting, so thru some trial and error, we found that adding a coat of Duplicolor Anodized Blue gave the best result.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Since the Dykem metal dye is very opaque, the metal it is applied to should be sanded, cleaned and brought to a high polish.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimjycALZ38C0ZrMpHrdi1fenPHQWSElt_X9N55BhYIBFpKjnWm7YUJFX8qAbCVOBpSElOwHb-e8E9NdyQBXT8Ck6y3YTCKTKUdfiNhprE9n7c4oRQ0dFy9Xeje-kULKILd-KegOBVcGKg/s1600/BlogPic11.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimjycALZ38C0ZrMpHrdi1fenPHQWSElt_X9N55BhYIBFpKjnWm7YUJFX8qAbCVOBpSElOwHb-e8E9NdyQBXT8Ck6y3YTCKTKUdfiNhprE9n7c4oRQ0dFy9Xeje-kULKILd-KegOBVcGKg/s320/BlogPic11.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">To polish the metal, I'm using this Mother's polishing ball </td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjStvQ1EY8wcRYB8_-NgCtgZh18MQZFmRSkIh-MoLn9RAbMfa303CFFnd_Iji-QiPG3e-CKjvoYB6ulgNaHoK7y3N_GUPkV0zxgxsH-2Jf-hHMT0joPSm_k2oJ0ILTSHF952Hxzwx59NdY/s1600/BlogPic12.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjStvQ1EY8wcRYB8_-NgCtgZh18MQZFmRSkIh-MoLn9RAbMfa303CFFnd_Iji-QiPG3e-CKjvoYB6ulgNaHoK7y3N_GUPkV0zxgxsH-2Jf-hHMT0joPSm_k2oJ0ILTSHF952Hxzwx59NdY/s320/BlogPic12.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The stack of sandpaper. 320, 400, 600, 800, 1000, 1500 and 2000</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh52E5WMESeE5tNoOWeumgS8zEBlFUwCo7k8NCQaXn3OUMn36HzdnlzMWi3OER_lVl4JNCCqX87SPHSIRz93iaosLOWo9vWW-cwbBLydZW4fgtzDL9NgcMNz45Z39Ohh0aBP3T0ajhTYSA/s1600/BlogPic15.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh52E5WMESeE5tNoOWeumgS8zEBlFUwCo7k8NCQaXn3OUMn36HzdnlzMWi3OER_lVl4JNCCqX87SPHSIRz93iaosLOWo9vWW-cwbBLydZW4fgtzDL9NgcMNz45Z39Ohh0aBP3T0ajhTYSA/s320/BlogPic15.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The various stages of shine, the best being the one that utilized the Mother's Aluminum polish on the far right</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFSUU4vCDvKpgwTXCnx-xkMqKnWCP22YhPUsWeFI2BZR-zo-V6VNkKS84RjWa7WlKwG07p0pO_hRlAlqOi-WHSy0fnzALvHsggP4BolASrh_mHifk8R0GBz4bwwAXL4_N_YfX-c9eYfsA/s1600/BlogPic16.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFSUU4vCDvKpgwTXCnx-xkMqKnWCP22YhPUsWeFI2BZR-zo-V6VNkKS84RjWa7WlKwG07p0pO_hRlAlqOi-WHSy0fnzALvHsggP4BolASrh_mHifk8R0GBz4bwwAXL4_N_YfX-c9eYfsA/s320/BlogPic16.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Prior to the first coat, I used the Dykem cleaning spray, which has acetone and other cleaners. Here's after the first light coat of Dykem</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv3sWIEtymvOiQ6HhzOevs7acmyxwN5mzfW9phRWgle3kJLXH6jd9MLkhMqCmEvIr4nkIGliYdVeULkJw3DFv_u9vicmOQjWqTCAw7EV3Xkk5iYzF3ZjQS420rd-iEeHdFf4BONYXzNhM/s1600/BlogPic17.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv3sWIEtymvOiQ6HhzOevs7acmyxwN5mzfW9phRWgle3kJLXH6jd9MLkhMqCmEvIr4nkIGliYdVeULkJw3DFv_u9vicmOQjWqTCAw7EV3Xkk5iYzF3ZjQS420rd-iEeHdFf4BONYXzNhM/s320/BlogPic17.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Second coat</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfz6poNVjT8NPA2WevXBcqEcpovU-ZY0-FWPAXCZlAkGHde8tLjle4MX00gGFMwW3b3U3eLOjIiy2sAkyJc1Xh3ZLMyh3TjVqgafA7P9tmrMh5Rjox0px1zK1_gvSZWOQJaZI5oLd558g/s1600/BlogPic18.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfz6poNVjT8NPA2WevXBcqEcpovU-ZY0-FWPAXCZlAkGHde8tLjle4MX00gGFMwW3b3U3eLOjIiy2sAkyJc1Xh3ZLMyh3TjVqgafA7P9tmrMh5Rjox0px1zK1_gvSZWOQJaZI5oLd558g/s320/BlogPic18.jpg" width="238" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Dykem piece with several coats of UV clear and regular clear coat. </td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"> Its a really amazing color. In hand, its purple. On camera, blue. It really depends on the angle. </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Now, with the Anodized Blue added to the mix...</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSR7kvhTni9nw9jJnpMnmyJUd-XTIVqaGVfKZzEDvtElWzVeWLGe0lcrrcJGA2V_IO_mRxLq-THlpzLp-6Q_muSYDDidptKb207ChrAG3y9UdWRXl9pA7cyFqrAEr6oYuUv2DjKopcx0w/s1600/BlogPic33.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSR7kvhTni9nw9jJnpMnmyJUd-XTIVqaGVfKZzEDvtElWzVeWLGe0lcrrcJGA2V_IO_mRxLq-THlpzLp-6Q_muSYDDidptKb207ChrAG3y9UdWRXl9pA7cyFqrAEr6oYuUv2DjKopcx0w/s320/BlogPic33.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Duplicolor Anodized Blue coat, just before the clear coats go on</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI2cARnL3LWTVlI3nG7H_zw5gQX2hqZ_48iEON1-J6GJc_eicOTClhdnLrIrRP08Cwf0_252lidYWV3GhsxJVJrpG6GIVTGV43teYlnU98Oz38_1SuzbEw-ke-bV8tKmbwLt_LzMUPeDk/s1600/BlogPic38.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI2cARnL3LWTVlI3nG7H_zw5gQX2hqZ_48iEON1-J6GJc_eicOTClhdnLrIrRP08Cwf0_252lidYWV3GhsxJVJrpG6GIVTGV43teYlnU98Oz38_1SuzbEw-ke-bV8tKmbwLt_LzMUPeDk/s320/BlogPic38.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Sample piece dry</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ-dHnPsnb9W4TVcBanmkCa5Ij0h6pzP7qTX1YofOLUFZyK5hdwsTV5CJlApNoA3QfEdjUBKXl7KO40lXDrz8bbIj5YB41-uvAWV45PVz0usmDLhN4g65Jww-LdJ5SkhUxDvK-kjGQlWo/s1600/BlogPic55.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ-dHnPsnb9W4TVcBanmkCa5Ij0h6pzP7qTX1YofOLUFZyK5hdwsTV5CJlApNoA3QfEdjUBKXl7KO40lXDrz8bbIj5YB41-uvAWV45PVz0usmDLhN4g65Jww-LdJ5SkhUxDvK-kjGQlWo/s320/BlogPic55.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Sample piece under flash</td></tr>
</tbody></table>
<br />
<span style="font-family: Verdana, sans-serif;">As you can see, its a really great mix of the blue with some purple hint to it. And, significantly cheaper to use.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">So, I began work on the parts that will get painted blue. And, some that were already painted blue and need to have it removed.</span><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2tlbG7nOgSia_Anioa7WQmB_n2I1MCzMZDM0fGUjDmzUS_vE_J52Qqj2kmE_9dMABd84deVdiOx0zPe82IL6H5ZdgSM67bw-dNF2_ZhIbEwNprPcapROvJTQFBEMcLsqpQsyiN26Etic/s1600/BlogPic47.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2tlbG7nOgSia_Anioa7WQmB_n2I1MCzMZDM0fGUjDmzUS_vE_J52Qqj2kmE_9dMABd84deVdiOx0zPe82IL6H5ZdgSM67bw-dNF2_ZhIbEwNprPcapROvJTQFBEMcLsqpQsyiN26Etic/s320/BlogPic47.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The Large Data Port, already painted blue, needs to be stripped so it matches the rest of the pieces in the new R2 Blue</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggzRhXOOnP2UHO2piiDTecj-yGo2O-eF6Bmm8_Lghl_xSNwfKYB3vvSZ_CKI4yzW9TxqAPpNb5NGldKxlaU0W7uIbdbK3Mee_CfWnyu67vHIdNKq6MFqoCWyWi47mo_otlFKSmLT-ciN4/s1600/BlogPic49.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggzRhXOOnP2UHO2piiDTecj-yGo2O-eF6Bmm8_Lghl_xSNwfKYB3vvSZ_CKI4yzW9TxqAPpNb5NGldKxlaU0W7uIbdbK3Mee_CfWnyu67vHIdNKq6MFqoCWyWi47mo_otlFKSmLT-ciN4/s320/BlogPic49.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Zip Strip made very quick work of this. Apply, wait for 10 minutes, wipe off...repeat as required. Be sure you have lot's of ventilation!</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFTk7v8UPMDr8bGHeqY3lcZdAgZ0WTYZH_0QgGT5ioxcPn-bLOfUO7nFUKdzqs-BLz9sv-kUoE1kkM_lQ4SYQvmBv9AL_rjO7eIqCg-SjysM0_iEt7ZrcL9_CvaiZs0t-M9R_Ox7OhB6Q/s1600/BlogPic53.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFTk7v8UPMDr8bGHeqY3lcZdAgZ0WTYZH_0QgGT5ioxcPn-bLOfUO7nFUKdzqs-BLz9sv-kUoE1kkM_lQ4SYQvmBv9AL_rjO7eIqCg-SjysM0_iEt7ZrcL9_CvaiZs0t-M9R_Ox7OhB6Q/s320/BlogPic53.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">And the Large Data Port with all the paint removed. I rinsed it some cold water and gave it a thorough wipe down then let dry.</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"> Next up will be applying the blue to this and other parts, ready to be painted.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcg-Kd93wlasAFOtbWx-h8XBBu7YTNCPfIQaX4ELyKBs-yN9ox-Tm4zg7DnBVOHy9Z9JYYOj9qCWwM6y43O_FYQSNNqXJ40oig1EKDDY6VBejq197B1RAUsOdbwQSeeyv6j3vx1kRJUg0/s1600/BlogPic50.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcg-Kd93wlasAFOtbWx-h8XBBu7YTNCPfIQaX4ELyKBs-yN9ox-Tm4zg7DnBVOHy9Z9JYYOj9qCWwM6y43O_FYQSNNqXJ40oig1EKDDY6VBejq197B1RAUsOdbwQSeeyv6j3vx1kRJUg0/s320/BlogPic50.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Utility Arms and the resin booster rockets, coated in a silver basecoat, ready for R2 Blue!</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"><br /></span>
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-48730244884490640932012-10-07T22:57:00.002-04:002012-10-07T22:57:51.597-04:00Ankle details and Battery Harnesses installed<span style="font-family: Verdana, sans-serif;">This weekend I spent some time on R2-D2 #2, namely on the ankle and battery box detail pieces.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Unlike R2-D2 #1, which has all aluminum detail pieces, I am trying to reduce weight by using resin versions of the detail pieces. </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">First, we verify how the parts should sit on the ankle and trace a light pencil line around them.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq7dKYQgXoBsBwVk8ebCDCwWJABRl8gw9OeHau-0UnotnsN4Y_iuA4RX-5mIVASSzNfGlLG7fe5n7vgAJp2wrxc7A1Y2Ta4HPE5GqGYtQdX77wArXwi9E-AR3bYX91r5pJycYhn_AFN8M/s1600/BlogPic01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq7dKYQgXoBsBwVk8ebCDCwWJABRl8gw9OeHau-0UnotnsN4Y_iuA4RX-5mIVASSzNfGlLG7fe5n7vgAJp2wrxc7A1Y2Ta4HPE5GqGYtQdX77wArXwi9E-AR3bYX91r5pJycYhn_AFN8M/s320/BlogPic01.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMk1M1qz4qTjdTpWjWSUqkduyTgwcKZ9fyAwQv22dMr3XdkIHfG7afsXXyhYurn4c-FGZERR6r3esuTQEsuHSc_gKKQgi0oliSZjaGsD4MoCYIARlI5Ein17v4qMM_6ykpy_tEYrLZ_to/s1600/BlogPic02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMk1M1qz4qTjdTpWjWSUqkduyTgwcKZ9fyAwQv22dMr3XdkIHfG7afsXXyhYurn4c-FGZERR6r3esuTQEsuHSc_gKKQgi0oliSZjaGsD4MoCYIARlI5Ein17v4qMM_6ykpy_tEYrLZ_to/s320/BlogPic02.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Next, I need to sand away the paint and primer on the metal ankle and roughly sand the back of the resin piece. Adhesives work best when they can grip and form a molecular bond with the surfaces. Otherwise, if they are just glued to the painted surface, if the paint chips or cracks, the detail piece will fall off.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAi28fz2ogb1SslLioO8W6IbMqdTCcQE85yQRs59V9Tw1sh_SCDf3orMTvHwyiMB5ao_j_oBYS-qOS0jJpPW0-0DzdugMyht_UVNKuJsYtmaKYuuAVE0zXgziYK-iBRnbTK4LkUEEzxFY/s1600/BlogPic03.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAi28fz2ogb1SslLioO8W6IbMqdTCcQE85yQRs59V9Tw1sh_SCDf3orMTvHwyiMB5ao_j_oBYS-qOS0jJpPW0-0DzdugMyht_UVNKuJsYtmaKYuuAVE0zXgziYK-iBRnbTK4LkUEEzxFY/s320/BlogPic03.jpg" width="320" /></a></div>
<br />
<br />
<span style="font-family: Verdana,sans-serif;">And we let that dry overnight. </span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZ1ehw6-Ln_U_W6ixek5pO-uxuB5EXgShmhPZZCDC6P0yxI0nLCvOf3SOplVMWPneKvshYAGrx9P-b8MMFemXlBLWK5oS_NB2AnQPkrgk-YyufMzccDSCr3Ob3zwV9jdStOCX0-X6Bf8k/s1600/BlogPic05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZ1ehw6-Ln_U_W6ixek5pO-uxuB5EXgShmhPZZCDC6P0yxI0nLCvOf3SOplVMWPneKvshYAGrx9P-b8MMFemXlBLWK5oS_NB2AnQPkrgk-YyufMzccDSCr3Ob3zwV9jdStOCX0-X6Bf8k/s320/BlogPic05.jpg" width="238" /></a></div>
<br />
<span style="font-family: Verdana, sans-serif;">Now the resin battery harnesses.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Like the ankle details, these were also molded with a metal gelcoat. The small pieces need to be cut and trimmed free.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYVtgkWcIOMszYFg-ah7RR0hD3_C6XtH_RZN3lR6A5IchMrp0TrNmY-PbZkkae5VZ18PGRM3UBLWau6c88xySO7VMC6SCWKUDWjE3L0eyGHr45ieXnAOe5ymva5XMEQqh3I6EKriDa2PQ/s1600/BlogPic07.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYVtgkWcIOMszYFg-ah7RR0hD3_C6XtH_RZN3lR6A5IchMrp0TrNmY-PbZkkae5VZ18PGRM3UBLWau6c88xySO7VMC6SCWKUDWjE3L0eyGHr45ieXnAOe5ymva5XMEQqh3I6EKriDa2PQ/s320/BlogPic07.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPbmsXv_feKfRouCc5Ijufs3qQ1Wxdmvmb_lxmNTFd2sg_QkDCmFOUvcBqm-OnWhwU7UMw-oSPMIcxNVZhwBmNbfhnDY-JXvmmKRjOforC2RL6pPhK8K6O_OfSj_FA8_grKygpsNDsBks/s1600/BlogPic09.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPbmsXv_feKfRouCc5Ijufs3qQ1Wxdmvmb_lxmNTFd2sg_QkDCmFOUvcBqm-OnWhwU7UMw-oSPMIcxNVZhwBmNbfhnDY-JXvmmKRjOforC2RL6pPhK8K6O_OfSj_FA8_grKygpsNDsBks/s320/BlogPic09.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDhF_ci7PtXvBs8CLUSbHqVzTmSuciatv7oXptTM8d7Hlsm9lXlS_ag-3OZS9AHA2O_hmDCOdMMP70fsAu077TxGUMeqpdIAmm0XVvHxBX3DIMhb28q3hmB1aaLEtCp2vFcj5Z7YyT8gk/s1600/BlogPic10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDhF_ci7PtXvBs8CLUSbHqVzTmSuciatv7oXptTM8d7Hlsm9lXlS_ag-3OZS9AHA2O_hmDCOdMMP70fsAu077TxGUMeqpdIAmm0XVvHxBX3DIMhb28q3hmB1aaLEtCp2vFcj5Z7YyT8gk/s320/BlogPic10.jpg" width="320" /></a></div>
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">The "seam" from the molding process needs to be sanded smooth. We also need to rough up the back surface.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmneDmzJ_cpd1O9p8mTrmS7K_2aXJLMzjxJYjxtoPlAcFyPX2KZjDGpAqSaDlcvC6k2dj_yNeST1x4-sawTlCSLjxrJwP5los7rr_IuQXBu14MUd-A8ZzdvwrwJC8t0ApzD5WXhPOjam8/s1600/BlogPic11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmneDmzJ_cpd1O9p8mTrmS7K_2aXJLMzjxJYjxtoPlAcFyPX2KZjDGpAqSaDlcvC6k2dj_yNeST1x4-sawTlCSLjxrJwP5los7rr_IuQXBu14MUd-A8ZzdvwrwJC8t0ApzD5WXhPOjam8/s320/BlogPic11.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUP69ju5vn6O0nE32dbQGj5HW1C9a7JxLpg528IChBm9jImh6ObrXC54a6tQXMKXExrh-Eiw6dXMXkM94DfSffmCaMPwsn3PCWy6NonryH8bsii3OJsZYpBzupx-RetdVeyKo-ns5PBVY/s1600/BlogPic12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUP69ju5vn6O0nE32dbQGj5HW1C9a7JxLpg528IChBm9jImh6ObrXC54a6tQXMKXExrh-Eiw6dXMXkM94DfSffmCaMPwsn3PCWy6NonryH8bsii3OJsZYpBzupx-RetdVeyKo-ns5PBVY/s320/BlogPic12.jpg" width="320" /></a></div>
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">The pieces would have had metal pins if these were the aluminum version. I drilled out an 11/64 hole so that a 10-24 thread rod segment can fit inside.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSisq_ujxGFeDyLQm8QSJynOxOw57Y-1oHiUQfQK2qkSpQlb9jqfN-VG0YWqjdj5UOjietKoNt8qF5CQbqYLlgI_-WYSn37y9uvI40DNfKsRWFa_WojuxYam4EayT348eCOnLZD5tW9gc/s1600/BlogPic13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSisq_ujxGFeDyLQm8QSJynOxOw57Y-1oHiUQfQK2qkSpQlb9jqfN-VG0YWqjdj5UOjietKoNt8qF5CQbqYLlgI_-WYSn37y9uvI40DNfKsRWFa_WojuxYam4EayT348eCOnLZD5tW9gc/s320/BlogPic13.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP3Z0HS2yqikN4Olpe8hyyA7Nkj9Qo-ZxZu_FR8umslXmMvzCIC59j3q6ZpocSOWkyZwnVV_FcY6t6nxuTUqbeKip4FKVMejWecmZDpaZc9OjBojwDZvQXX7osnrnDl-b7UUMXv1L5c1c/s1600/BlogPic15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP3Z0HS2yqikN4Olpe8hyyA7Nkj9Qo-ZxZu_FR8umslXmMvzCIC59j3q6ZpocSOWkyZwnVV_FcY6t6nxuTUqbeKip4FKVMejWecmZDpaZc9OjBojwDZvQXX7osnrnDl-b7UUMXv1L5c1c/s320/BlogPic15.jpg" width="320" /></a></div>
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Next, I use a 2 inch long 10-24 thread screw, measure how much it takes to fit inside the harness mounts and cut it up.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY3nNrFXe9TNo1adQ2Qw2h7QtX-ORLs5FAPWFqAYpcw_A6R164jxyGTOj-WvY-A7fx1-wEHivCM0FRFdndYkmiXrtqPA7SlECrOYcFyC75uRpSjZnTqzGfIJRleaMXMICaNnQOBi3DmAQ/s1600/BlogPic16.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY3nNrFXe9TNo1adQ2Qw2h7QtX-ORLs5FAPWFqAYpcw_A6R164jxyGTOj-WvY-A7fx1-wEHivCM0FRFdndYkmiXrtqPA7SlECrOYcFyC75uRpSjZnTqzGfIJRleaMXMICaNnQOBi3DmAQ/s320/BlogPic16.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLVwOjfT7vIU_6cuhK9xYhB-n5RzjDmUb-gLmeTrxW0lKbd5c5luezPYTavat4WfgOSyFyrVxekUr60Aqwx55UC5ScPv5NCaoC0iTmqJbOJhe2otOU5dcc3T_JaAy2Cm8-8sK-cgswPdc/s1600/BlogPic17.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLVwOjfT7vIU_6cuhK9xYhB-n5RzjDmUb-gLmeTrxW0lKbd5c5luezPYTavat4WfgOSyFyrVxekUr60Aqwx55UC5ScPv5NCaoC0iTmqJbOJhe2otOU5dcc3T_JaAy2Cm8-8sK-cgswPdc/s320/BlogPic17.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIIN1JKQemLhwXJtsQLNbBw2XuOAHHycWWyTlfkz3K3H_c3nTVTV5VuexLGDmaQ-NtUpOUwzuEwGd7VHgfvzzJ1Ki4RQFRp-XOZoMrWjFdahoeVK2eqm4c1WJf0-EY8WFZNkhiLa_-of0/s1600/BlogPic19.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIIN1JKQemLhwXJtsQLNbBw2XuOAHHycWWyTlfkz3K3H_c3nTVTV5VuexLGDmaQ-NtUpOUwzuEwGd7VHgfvzzJ1Ki4RQFRp-XOZoMrWjFdahoeVK2eqm4c1WJf0-EY8WFZNkhiLa_-of0/s320/BlogPic19.jpg" width="239" /></a></div>
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Now its time to get the harnesses lined up on the battery box, mark their position, sand away some paint and let the silicone out!</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjELgkTt9h7AQXX6avs4PBfmB1zY4new8_g2nArp8-OrwqIgtFzvxHFldiNbnI1wvuqftB0oI2ksW3ewlw9vh9EN7cTsQ73nIPE9bSJ6SLYfmNtx9JxIYw0X412Euq7DXOB8GdFLEzhNaA/s1600/BlogPic20.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjELgkTt9h7AQXX6avs4PBfmB1zY4new8_g2nArp8-OrwqIgtFzvxHFldiNbnI1wvuqftB0oI2ksW3ewlw9vh9EN7cTsQ73nIPE9bSJ6SLYfmNtx9JxIYw0X412Euq7DXOB8GdFLEzhNaA/s320/BlogPic20.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfRDXgjh5sHSAKjHG54USU4EQ43Of9VaPBRxfsmSjkK1u2h-TO7t4A-b82_91MJdeTyfZmFwEw2kSW7_9kcVcxqkFofnXqKRE8aPUxMy5eHqMCLGu5jMAnvZDWtg5EjBV9i0-D4UTPWXQ/s1600/BlogPic22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfRDXgjh5sHSAKjHG54USU4EQ43Of9VaPBRxfsmSjkK1u2h-TO7t4A-b82_91MJdeTyfZmFwEw2kSW7_9kcVcxqkFofnXqKRE8aPUxMy5eHqMCLGu5jMAnvZDWtg5EjBV9i0-D4UTPWXQ/s320/BlogPic22.jpg" width="238" /></a></div>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL_m5kjtQMY_K2h5y7Nsozoq2Kk_md-DF4JagQZrDT7XKATGAQt1QBxhjJg_KhT8Ir-ivfO-Wxuonbo0BT-HRJMKYvPnjnA7cnti-P8eXZskH9eS8bo5pZjkne3-qjRIqkm0VUAn4k5vY/s1600/BlogPic23.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL_m5kjtQMY_K2h5y7Nsozoq2Kk_md-DF4JagQZrDT7XKATGAQt1QBxhjJg_KhT8Ir-ivfO-Wxuonbo0BT-HRJMKYvPnjnA7cnti-P8eXZskH9eS8bo5pZjkne3-qjRIqkm0VUAn4k5vY/s320/BlogPic23.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Lightly use some 80 grit sandpaper to remove paint. You can also touch up the areas later if you remove too much.</td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiid_Xp7edIBssGCJUSrPtmSYvfhPLi81s27CNbhkTAOlsTDHGRt1KstBRWuZ8INV6TW25HFkfX3tcNh_1Q2JXUTLQt4ZlmEq6bMpJ3Ex5pSTxleHGFCeN-3z0swYjjMBJv5JjAA6aumpY/s1600/BlogPic24.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiid_Xp7edIBssGCJUSrPtmSYvfhPLi81s27CNbhkTAOlsTDHGRt1KstBRWuZ8INV6TW25HFkfX3tcNh_1Q2JXUTLQt4ZlmEq6bMpJ3Ex5pSTxleHGFCeN-3z0swYjjMBJv5JjAA6aumpY/s320/BlogPic24.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">A dab of silicone, then apply the resin part on top. I used a pop sickle stick to add more and guide it where needed </td></tr>
</tbody></table>
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF_nQtEoHZJq9d-fARECLzoF79lksCea08MHOFCPLf0cG_KfcPx4wWqhIkkjSWtgYOxgWskccd2uDh6309l2tKZCzmWa6vEyZMid9_v80GhcpACyiEDDMSvIMVr1yqdGhU3vbN4mbEBCU/s1600/BlogPic26.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF_nQtEoHZJq9d-fARECLzoF79lksCea08MHOFCPLf0cG_KfcPx4wWqhIkkjSWtgYOxgWskccd2uDh6309l2tKZCzmWa6vEyZMid9_v80GhcpACyiEDDMSvIMVr1yqdGhU3vbN4mbEBCU/s320/BlogPic26.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Voila! Done and left to dry overnight.</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<span style="font-family: Verdana, sans-serif;"> </span><br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-41846581080111715752012-09-23T00:56:00.000-04:002012-09-23T00:56:03.111-04:00Working on the aluminum skirt for R2-D2 #2<span style="font-family: Verdana, sans-serif;">Over the past few nights I've been working on the aluminum skirt piece, which is what attaches to the bottom of R2-D2's body.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">There are different materials to chose from with the skirt. There's a fiberglass version available which just needs to be mounted, a styrene (plastic) one and the aluminum one. Mine is an older version made by JAG and just needs to have the slab pieces attached. Newer versions already have the cut outs on the skirt for the pieces to attach to, so no need to measure and mark where to place them. </span><br />
<br />
<span style="font-family: Verdana, sans-serif;">After marking off where each slab will go in pencil, its time to use a center punch and punch where the holes are to be drilled. </span><span style="font-family: Verdana, sans-serif;"><span style="font-family: Verdana, sans-serif;">This prevents the drill bit from wandering while drilling. The slabs aren't very wide compared to the 10-24 thread screw.</span></span><br />
<br />
<span style="font-family: Verdana, sans-serif;">I opted to attach the skirt to the bottom frame ring plus the frame rods.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgADv-qo1iimBjtObj4QBjwKYjHGWawjblG3VIHnYPDAfeUXajgQkk0MDAG763mN_oDdxNKFmeUaILtYE1M05ac1KVBltHE0mmzZwqZEgPPych9bN_-5AptY1E8pxIV3GZ1d6Jf2V5yZIc/s1600/BlogPic17.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgADv-qo1iimBjtObj4QBjwKYjHGWawjblG3VIHnYPDAfeUXajgQkk0MDAG763mN_oDdxNKFmeUaILtYE1M05ac1KVBltHE0mmzZwqZEgPPych9bN_-5AptY1E8pxIV3GZ1d6Jf2V5yZIc/s320/BlogPic17.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0MMUrKimVzr4uJK7bgBP4R8eG0MFvW9_IWPm94v3PLYsXfvBG9OYYhDfootL-xYZAlgQA2Tdd4nW3mrHBl_aMdeZvJbkQ3ehcuHzm-VVzmmH7419OqXwa6qUmbk1LioRCnn8C_QHH57w/s1600/BlogPic18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0MMUrKimVzr4uJK7bgBP4R8eG0MFvW9_IWPm94v3PLYsXfvBG9OYYhDfootL-xYZAlgQA2Tdd4nW3mrHBl_aMdeZvJbkQ3ehcuHzm-VVzmmH7419OqXwa6qUmbk1LioRCnn8C_QHH57w/s320/BlogPic18.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;"> Now that the holes are drilled out, its time to place the slabs where they will be mounted permanently. With the holes drilled and the skirt elevated by the frame rods, its just a matter of marking the position of the holes with a Sharpee.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOhJspZG3ceIkP4cs3uPZrDKWfm2BRiQeRbmWyBof8PYQJv330Mh1kBwuonXj9WVNkLDp5rmwJKD3EUct-W-aR46GGhsabC0kB-LP_MJjGWzFt4Y8TpqY9-DqC1lKHmYryha5hUqsPzfs/s1600/BlogPic20.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOhJspZG3ceIkP4cs3uPZrDKWfm2BRiQeRbmWyBof8PYQJv330Mh1kBwuonXj9WVNkLDp5rmwJKD3EUct-W-aR46GGhsabC0kB-LP_MJjGWzFt4Y8TpqY9-DqC1lKHmYryha5hUqsPzfs/s320/BlogPic20.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVWJbZzg63YRfn1Ujs2Bft0bhO9A08nJW8c1WKDBtTnXZIs-LslvO-eVEJEItb2Z-vWWp0IBHJ4Abb-vW26bBh4OOMg7fjF8pF0BGK0uRfvKioi-e3yOCqODbjkiyCDtO_3gxKWc6iG0k/s1600/BlogPic21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVWJbZzg63YRfn1Ujs2Bft0bhO9A08nJW8c1WKDBtTnXZIs-LslvO-eVEJEItb2Z-vWWp0IBHJ4Abb-vW26bBh4OOMg7fjF8pF0BGK0uRfvKioi-e3yOCqODbjkiyCDtO_3gxKWc6iG0k/s320/BlogPic21.jpg" width="320" /></a></div>
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">Then I used the center punch to make sure the drill bit stays put.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4-gjUHtKeDCJ9OMTOK2M5LsYYdApJ9yQadfWbulkL_MyhNR77H4eZM0gOL5c5_QazecUOp0WNBB42ZSoBrOrUKzlykADuXGuBRmQZAkkmIh-dCl4tTqx1NJ5vZU_MQ4afXlnHK4jf-0Y/s1600/BlogPic22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4-gjUHtKeDCJ9OMTOK2M5LsYYdApJ9yQadfWbulkL_MyhNR77H4eZM0gOL5c5_QazecUOp0WNBB42ZSoBrOrUKzlykADuXGuBRmQZAkkmIh-dCl4tTqx1NJ5vZU_MQ4afXlnHK4jf-0Y/s320/BlogPic22.jpg" width="320" /></a></div>
<br />
<span style="font-family: Verdana, sans-serif;"> Now I was planning to only drill part way and tap the hole, making sure to not drill thru the other side. However, with my tap and die kit, the hole wasn't deep enough to get more than 2 turns, not enough threads to secure it in place. On my first R2's skirt, I used various epoxies and the slabs eventually popped off. Since I drill and bolted them into place, never an issue. That said, I decided to drill all the way thru and tap the entire hole.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Each hole was drilled out with a 5/32 drill bit, which allows for a 10-24 tap to make the threads nicely. To secure them in place I am using a 3/8" inch 10-24 thread screws and a split-lock washer.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs9FEnLMrgL9F3a8iFK80ykySYAgrBSSYV0hD1fLnQRAh3sIOY1QLbJnj0Xh59SRGv0X-eMo9kR3JAlJjf7CFu8JxDcbo62zfaGyA8uacM-jHIdwIQiuOO81zztBKkoP2OEQLegc-IVRw/s1600/BlogPic14.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs9FEnLMrgL9F3a8iFK80ykySYAgrBSSYV0hD1fLnQRAh3sIOY1QLbJnj0Xh59SRGv0X-eMo9kR3JAlJjf7CFu8JxDcbo62zfaGyA8uacM-jHIdwIQiuOO81zztBKkoP2OEQLegc-IVRw/s320/BlogPic14.jpg" width="320" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">To smooth out all those little holes for painting, I am using JB Weld, which when dry, sands nicely.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<span style="font-family: Verdana, sans-serif;">To keep the JB Weld from sliding around while wet, I'm using some painters tape rolled up to keep it in place. Then, its just a matter of sanding smooth, touching up as needed and a few coats of satin white paint.</span><br />
<span style="font-family: Verdana, sans-serif;"><br /></span>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxRBgkeTlP202cESVl_I8Ij_zdNizcJSziEor1RUNk9qxwQTU07UjmM0eBm95QmdQXX_GkX584OKckI6JH_zzEXNKzWgodcXHf7MqatfXcTSeuO9NXoTo622vES33dmoBi9anE0nNXvAE/s1600/BlogPic24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxRBgkeTlP202cESVl_I8Ij_zdNizcJSziEor1RUNk9qxwQTU07UjmM0eBm95QmdQXX_GkX584OKckI6JH_zzEXNKzWgodcXHf7MqatfXcTSeuO9NXoTo622vES33dmoBi9anE0nNXvAE/s320/BlogPic24.jpg" width="320" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCFVviGUONFReGaZqMCu5B2f5Haw18kuiukuYtTyyfNGNlZ6AO3gsdo4hY4-3-1pMtleGjFW9lm3GmPckBOfX7mihHzH9Ef_PDCY1vvej6cRu-vnBmhZMC57K9TBZgQtQ4Or-MN6lzqAc/s1600/BlogPic15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCFVviGUONFReGaZqMCu5B2f5Haw18kuiukuYtTyyfNGNlZ6AO3gsdo4hY4-3-1pMtleGjFW9lm3GmPckBOfX7mihHzH9Ef_PDCY1vvej6cRu-vnBmhZMC57K9TBZgQtQ4Or-MN6lzqAc/s320/BlogPic15.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaGZ2ePtn7woVQc4k-9CRKWIJ_mhvL3IlsS6sa6k_bkkgC94LMQp98KlKvRFRpq0H_NNIKzf5R9-Wt1bWFk69gImGqwsyvvsS3-D4EzQQO-NsfYZflcigsFbn0pxzt2JkXXDNZYxr9T-s/s1600/BlogPic27.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaGZ2ePtn7woVQc4k-9CRKWIJ_mhvL3IlsS6sa6k_bkkgC94LMQp98KlKvRFRpq0H_NNIKzf5R9-Wt1bWFk69gImGqwsyvvsS3-D4EzQQO-NsfYZflcigsFbn0pxzt2JkXXDNZYxr9T-s/s320/BlogPic27.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF0LYF5iR4V6avfQ-V4GYfqHfXNO7AK_gl5Iy4H6pYk8sWHOaxWYN1Lgb6ub5ulUCQ3jH-hdHXthP1mlozQNi4TNUp8yeww-YJaLzPdJ4tdM_aj7LJqZWphc3bU3-9v-8h_di2L0Yp2Y8/s1600/BlogPic28.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF0LYF5iR4V6avfQ-V4GYfqHfXNO7AK_gl5Iy4H6pYk8sWHOaxWYN1Lgb6ub5ulUCQ3jH-hdHXthP1mlozQNi4TNUp8yeww-YJaLzPdJ4tdM_aj7LJqZWphc3bU3-9v-8h_di2L0Yp2Y8/s320/BlogPic28.jpg" width="239" /></a></div>
<span style="font-family: Verdana, sans-serif;"><br /></span>
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-46099552918899648262012-08-14T21:48:00.000-04:002012-08-14T21:48:32.221-04:00Painting gelcoated resin pieces<span style="font-family: Verdana, sans-serif;">Last week i worked on some resin detail pieces made by Wayne Orr. These all have a gelcoat of metallic finish on them.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh811XH7MEuBFAa9IJefex2t3n_2Dgvq0rPJmMZaDuzQRSHRGPCjtCK6-__hXNxwVq-ReqRyMaRy8u7SVyjR7IAbujFzr-0EHwXP8IIQvxvPWYn90WBwZaRJSFvSRyHiUtLeC7r3enJRgg/s1600/pic+047.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh811XH7MEuBFAa9IJefex2t3n_2Dgvq0rPJmMZaDuzQRSHRGPCjtCK6-__hXNxwVq-ReqRyMaRy8u7SVyjR7IAbujFzr-0EHwXP8IIQvxvPWYn90WBwZaRJSFvSRyHiUtLeC7r3enJRgg/s320/pic+047.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIUkJ5qFzbm8Ptu4_XSISDAPtxiERkQow5Nq7fv5uLhReUd7Hq519BZ_kHZ_LfV5toK5TlnUaIIgADC6SPD4qWK8KuBF9FzMeaCzXYFzSLw4vS1ZIz5dXFQxzQINVlUBJal2OVVHs3JK0/s1600/pic+049.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIUkJ5qFzbm8Ptu4_XSISDAPtxiERkQow5Nq7fv5uLhReUd7Hq519BZ_kHZ_LfV5toK5TlnUaIIgADC6SPD4qWK8KuBF9FzMeaCzXYFzSLw4vS1ZIz5dXFQxzQINVlUBJal2OVVHs3JK0/s320/pic+049.jpg" width="320" /></a></div>
<br />
<span style="font-family: Verdana, sans-serif;">After trimming the excess material from the molding process, its time to use painter's tape on the spots that we don't want painted. The inside of the octagon port will take a bit of time to cover up precisely.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSmIIBIo4aG-f5ZfWAIUZKr9aXUervSgU5pL-I4S5nae2kyPzAfqORj_k5dvbxfB2eI0EcTlF20tbdgWpAHrxIS2Kp_61Iva0PLa0UQ2gMWWZp31bynP7Fc-BT8oZgmOAVqIdBHN86ZHQ/s1600/pic+050.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSmIIBIo4aG-f5ZfWAIUZKr9aXUervSgU5pL-I4S5nae2kyPzAfqORj_k5dvbxfB2eI0EcTlF20tbdgWpAHrxIS2Kp_61Iva0PLa0UQ2gMWWZp31bynP7Fc-BT8oZgmOAVqIdBHN86ZHQ/s320/pic+050.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis7S8n6ITQe0fWKhidWY4x6BuhyphenhyphenYpC2PSN2PsXOajN9RsI1UGQRIMQ941n_vqAuHOiitnSg1r6FcuKohM0lmEOK-nc_zLrRuEhHZ__mY3QNDYdXigPUdvdA9irrZVjeAeBAzLVVfnINf8/s1600/pic+051.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis7S8n6ITQe0fWKhidWY4x6BuhyphenhyphenYpC2PSN2PsXOajN9RsI1UGQRIMQ941n_vqAuHOiitnSg1r6FcuKohM0lmEOK-nc_zLrRuEhHZ__mY3QNDYdXigPUdvdA9irrZVjeAeBAzLVVfnINf8/s320/pic+051.jpg" width="320" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2YHERub_-2W9tmmcYk3lIy1RLYQop6-UQe5xzPiFdKMU1m6jl6c-Zckdzl4soWIHmC1KFlEYTOqLsEHIzP2b37peLzA7jrQkO2EURFWlp8gUMhIs7MttMaRHdFGNh-97oN0niugnb09Q/s1600/pic+052.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2YHERub_-2W9tmmcYk3lIy1RLYQop6-UQe5xzPiFdKMU1m6jl6c-Zckdzl4soWIHmC1KFlEYTOqLsEHIzP2b37peLzA7jrQkO2EURFWlp8gUMhIs7MttMaRHdFGNh-97oN0niugnb09Q/s320/pic+052.jpg" width="320" /></a></div>
<br />
<br />
<br />
<br />
<span style="font-family: Verdana, sans-serif;">With the pieces covered in tape, the next step is to rough up the gel-coated surface. I did some searches on the Internet and most of the sites I looked at suggested 400 grit sandpaper. This roughs up the surface of the gelcoat and gives the paint a surface for adherence.</span><br />
<br />
<span style="font-family: Verdana, sans-serif;">Next up is the adhesion promoter and R2 Blue </span><br />
Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.comtag:blogger.com,1999:blog-639175500060613814.post-42604536927763368682012-07-30T22:56:00.001-04:002012-07-30T22:56:17.456-04:00Test fitting booster pieces and battery boxes attached<span style="font-family: Verdana,sans-serif;">After all the work I've done on these aluminum pieces, I wanted to do a test fit to make sure they would work out alright.</span><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvAEyeSz-mnbmVUuiVW7fN-wkvZugr_pbsv-7XbSof2bMmG37RK7XS9U5tA7-iE0PqESqJIzlUl4HAvOGl1XIlAC9CbcVeBE_hLdKBRclUNddh2f6zdqgNKZJf0Q_BXxBY6pnWpbabKF8/s1600/IMG_0712.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvAEyeSz-mnbmVUuiVW7fN-wkvZugr_pbsv-7XbSof2bMmG37RK7XS9U5tA7-iE0PqESqJIzlUl4HAvOGl1XIlAC9CbcVeBE_hLdKBRclUNddh2f6zdqgNKZJf0Q_BXxBY6pnWpbabKF8/s320/IMG_0712.jpg" width="238" /></a></div>
<span style="font-family: Verdana,sans-serif;">Everything went together very smoothly. One complication I can see is that the rocket booster will be tricky to properly align when extended. Note to self on that!</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<span style="font-family: Verdana,sans-serif;">I also tested out the fit for the swing arms.</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh844axEGrEJ6witdbAZibtspMX4sytYiasitFn9PsoXu8_KdPTIcRelV8k9-oGcwwc95KrIQ02FGubpnrJZYQ-n6bRgnMLstCcT-atDb00Ubkd9Rrp1TEJ15kdvG2ZOEsLzDfqRvoX3EM/s1600/IMG_0713.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh844axEGrEJ6witdbAZibtspMX4sytYiasitFn9PsoXu8_KdPTIcRelV8k9-oGcwwc95KrIQ02FGubpnrJZYQ-n6bRgnMLstCcT-atDb00Ubkd9Rrp1TEJ15kdvG2ZOEsLzDfqRvoX3EM/s320/IMG_0713.jpg" width="238" /></a></div>
<br />
<span style="font-family: Verdana,sans-serif;"></span><br />
<br />
<br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<span style="font-family: Verdana,sans-serif;">I don't quite have the right shoulder screw for the piece to smoothly articulate. But, with some minor bending here and there, it all fits.</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<span style="font-family: Verdana,sans-serif;">Next up was to get out the fine files and shave away and bumpy spots from the CNC cutting.</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2tGM8KuCuPrbedEith9ti0aRtiPE-xiJcCsnIduhKJuTFMViFu1Ejrv0y7FOGPuy0SQEMPArqVdGg-_BLjkAQzzZBDsbOk6tQq27GmWHIFhVj_FJbgh55OP-OejzIjJ_cmYgWDj0k7oI/s1600/IMG_0736.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2tGM8KuCuPrbedEith9ti0aRtiPE-xiJcCsnIduhKJuTFMViFu1Ejrv0y7FOGPuy0SQEMPArqVdGg-_BLjkAQzzZBDsbOk6tQq27GmWHIFhVj_FJbgh55OP-OejzIjJ_cmYgWDj0k7oI/s320/IMG_0736.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">After a few minutes of filing, a much smoother surface.</td><td class="tr-caption" style="text-align: center;"><br /></td></tr>
</tbody></table>
<span style="font-family: Verdana,sans-serif;">Next up was to finish attaching the detail pieces to the outer feet and then attaching the battery boxes.</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<span style="font-family: Verdana,sans-serif;">The battery boxes hang from a keyhole cut out in the feet. It takes a few moments to line up the box, mark the spots and drill/tap a hole. The battery boxes hang from a 10-24 thread pan-head screw.</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS0K2GG_8v4NbMD9HTYlVvZevPTs6MqFaL9R47F_Z2cockpxBfN1hwxtfOrEmOem3HM9AT1JLDOabBmv1TeCdfV0mK9Gb0IA5xo80-jhAgRoWavQ4BvqjpABgUSqd2CgVJmzuxzDdY4Yo/s1600/IMG_0737.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS0K2GG_8v4NbMD9HTYlVvZevPTs6MqFaL9R47F_Z2cockpxBfN1hwxtfOrEmOem3HM9AT1JLDOabBmv1TeCdfV0mK9Gb0IA5xo80-jhAgRoWavQ4BvqjpABgUSqd2CgVJmzuxzDdY4Yo/s320/IMG_0737.jpg" width="238" /></a></div>
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<span style="font-family: Verdana,sans-serif;">One foot down, on to the next...</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj0sbW_2z_oZl8sfdE7dT3TGAYHq-Sixtvhl2xUNFeOivKaxHkdlLIVM5qGzNq4srWrDGP-YhdZOgJy-S5XXP7qDfnv3SceVAKiv77YUEkSL7DVcTPj3KxdclhiJN_jOj3Gg198s221VE/s1600/IMG_0721.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj0sbW_2z_oZl8sfdE7dT3TGAYHq-Sixtvhl2xUNFeOivKaxHkdlLIVM5qGzNq4srWrDGP-YhdZOgJy-S5XXP7qDfnv3SceVAKiv77YUEkSL7DVcTPj3KxdclhiJN_jOj3Gg198s221VE/s320/IMG_0721.jpg" width="320" /></a></div>
<span style="font-family: Verdana,sans-serif;"></span><br />
<br />
<br />
<span style="font-family: Verdana,sans-serif;">Next up for these guys will be the battery harnesses and ankle details, which need to have the R2 blue paint applied. Both pieces are resin copies of the aluminum pieces. With this R2-D2, I am striving to cut down weight where I can, so every little savings adds up!</span><br />
<span style="font-family: Verdana,sans-serif;"><br /></span><br />
<br />
<span style="font-family: Verdana,sans-serif;"> </span>Paulhttp://www.blogger.com/profile/03213361742211982100noreply@blogger.com