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.