Because I do a lot of traveling with my R2 I decided to build a newer (better) transport box. I’ve called it box 2.0 😏. I’ll be building a similar one for BB-8 as well. Also when the box isn’t in use I just unscrew the 20 screws and it’s instantly a flat pack for easy storage.
Now that I’ve come pretty far with the body work I’ve started to go back into the internal workings. The pictures below shows pretty much about how I’ve figured out the body spinning and rotation. The orange bin I added to give a little extra weight so that original 6kg weight in the bottom is now 8kg. The extra weight made a world of a difference. I left extra space in those bins in case I wish to bump it up to 10kg-12kg for even more stability. Once I’ve attached the head and such I’ll see the handling. In the pictures below I’ve not included the head movement mechanisms even though its ready to install. I want to get the main rolling and spinning dialed (lined-up) first. I’ll probably do a video of the moment in a week or so. Anyway, here are the latest pictures:
I’ve gotten a few questions about what kind of filler I’m using and is it durable. Well I’m using a chemical wood done by Plastic Padding. They make all kinds of fillings but this one has worked best for me, it’s very durable, adheres well to my HDPE plastic and makes perfect door panel seals. Once it’s all is painted and weathered it will look perfect! Here’s a closeup.
Well I haven’t posted for a few weeks but I have been very much at. I’ve done all the primary testing with my internal mechanisms and so far so good. It will of course require some tweaking. I’ve now started working on attaching the outer shell while leaving access 3 panels in the appropriate places. Its turning into a real jigsaw puzzle but a lot of fun seeing it all take shape after so many month reworking the internal workings. I will also start covering the sphere with a special plastics primer paint which will make the over coatings stick much better. I’m not going to attach the final external panels until I’m 110% sure it will flawlessly. Once the final panels are attached I won’t be able any longer to remove internal fame nor extra weights. I’ll post more pictures and perhaps video of the internal workings, Anyway here’s a few pictures to see the progress:
Its time to get back at some body work. I needed a little break from the internals for a while while I’m waiting for parts on order.
About my outer shell, as mentioned in a few posts earlier I’m using an outdoor garden (ball) lamp as the main material. It just so happens to match the actual size of the real BB-8. The plastic is HDPE High-density polyethylene, which is super strong and yet very light and easy(ish) to cut. A Dremel works perfectly on this for cutting and carving. The only issue with with kind of material is that it doesn’t like being glued in other words NO traditional glues work. I finally a tracked down a “Poly-bonder” adhesive that should work and I’m waiting for that delivery from the UK. The “Pie panels” will be totally cut out of the sphere but the paneling details will be carved in. The most tedious part of this process was to draw all the paneling on the ball first before cutting. I must have measured and remeasured a dozen times to get them lined up, so it took a few days to complete. Because I have a life, doing this kind of tedious process took a while but the drawings are done and I can begin cutting out the 2 actual (planned) working panels.
After working on my internal “buggy” in the the body I wasn’t getting the traction that I was hoping for so I’ve done a slight comprise to my construction. I’m reimplementing from my original design my fixed middle pivot point idea so the entire internal structure is mounted on that fixed pivot point with a high torque motor on one side and a hollow bar on the other side. The hollow bar in great for when I’m installing lights and working doors to the outer shell and not getting the cables twisted. Its hard to explain but the pictures show everything. I’m also using super strong plexi-glass on every part when possible to make visibility unobstructed. I did a test drive and it works as I hopped.
I’m waiting for a delivery of a new wind-shield-whipper motor that will spin the bottom weight. My next post will be about working on body shell itself.