I’ve completed the build of my Wall-e about 5-6 years ago and had the desire to do some upgrades awhile now. Since last year I’ve really come to grips with 3d printing printing minor parts for R2 and other smaller projects but now have been giving Wall-e an “extreme makeover”. All the major parts of my Wall-e needed some TLC. So since June until September I’ve been letting my printers run 24/7 printing new CAD designed and fabricated parts in the hundreds. Specifically, the new treads are the biggest change. My original treads were made of foam rubber which I weren’t the best solution as they gripped the ground too well, waering out both the motors and motor controllers. These new ones glide a lot better and still have good traction where needed. The short list of new parts is:
- Totally new neck and connectors
- Completely printed head and eyes
- 70 new treads 40% solid PLA
- new conveyor belt gears of 75% solid PLA
- new BnL hubcaps all around
- 2 new arms including shoulder hub / pulleys
Next year the Wall-e film is 10 years old and I thought I’d have him in prime condition for the coming year of scheduled and surprise events (more to follow). So here are a few pictures of newly fabricated parts.
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:
I’ve now started working on the internal mechanisms and well it’s kind of like building a ship in a bottle where I construct on the inside a platform, mini scaffolding for moulding all the working parts, batteries etc. Its actually a fun challenge and equally important to get everything right the first time 😉
This past weekend was the 2nd and now annual ComicCon in Stockholm in the enormously impressive Friends Arena! This was a weekend of many memorable moments that I’ll never forget. I brought my R2 and Wall-e to this event along with fellow R2 Builders Sweden and Nordic Legions Members. It was probably the best event I’ve ever been a part of in all my past 8 years of conventioning.
From my droid perspective My R2 took over the EA Games Star Wars: Battlefront display as the centerpiece:
My Wall-e was so popular it was beyond humbling with MANY compliments and loving gestures from kids and adults alike. I’ve never felt so much love for any of my previous projects as I got for my Wall-e this past weekend. These pictures only tell part of the story. But they do show why I love to have this crazy hobby.
Wall-e performed like a real champ with only a few minor glitches. My latest tread adjustments worked awesomely. I tightened up the treads and gears to prevent the treads from derailing. This 3,5 year project with Walle has finally paid off. For those that don’t know Walle was never built for the Disney film. It was all CGI. So getting the digital Walle to work in the real physical world was the ultimate challenge.
And throughout the weekend there was was this constant feeling of excitement whenever Walle caught a visitors eye.
On Saturday I and the R2 Builders got the chance to present our R2 and BB-8 builds to a standing room only 200+ public. It felt so awesome!!
Now that this event is over its time to focus on my BB-8. I have quite a few events scheduled this autumn/winter season but BB-8 completed is priority #1
As of a few hours ago my Wall-E has become an officially indoctrinated Nordic Reel Icon member. Its a charity organisation that consists of iconic film characters that do charitable events around Scandinavia. The original club was started in the UK with the same name. Now it has expanded to Scandinavia. Here’s the link to their web page: Nordic Reel Icons
As mentioned in an earlier post I’ve been reworking my ideas about printing as many parts possible. Well thanks to the work on 3D files by the BB-8 Builders Club and help from my good friend Micke Askernäs my domes has taken shape. All that’s left with the dome is “just” sanding, painting and lighting up.Then I can put focus back on the main body 😉
I’ve finally begun printing out parts for the BB-8 dome on my 3D printer. Its really a unique feeling and luxury to replicate (fabricate) parts this way. Its a time consuming process but very easy. Wow, modern times!