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  Finished? (Nope)
Posted by: Prettyfloralbonnet - Yesterday, 04:40 PM - Forum: Prettyfloralbonnet - Replies (2)

As of October 2018, I still have the battery boxes, some pieces in the rear panel, and having all of my planned electronics hooked up and working.  Instead of adding updated progress pics as we go down, I'll leave the most current version at the top of the post.

September '18: missing some side panels, battery boxes, rear inserts for panel.  Movement and sound work.
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August '18: missing some doors, greebles, and panels
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April 2018: some sanding, filling, and priming done (this is when I thought I'd be finished)
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  Painting & Finishing
Posted by: Prettyfloralbonnet - Yesterday, 04:03 PM - Forum: Prettyfloralbonnet - No Replies

Forgive the initial mess in this post as I find and add pictures to this...

My usual process for "finishing" a part went something like this: Mouse sander for large coverage ~120 grit -> wood filler for large gaps/holes -> more sanding -> Rustoleum Auto Filler Primer (2-3 coats) -> more sanding -> Bondo spot putty -> more sanding.  In the beginning, I did just one round of that routine but by the time the April maker faire rolled around, I realized it wasn't going to be enough.  

Paints and primers used: Rustoleum Ultra Cover Flat Grey Primer, Rustoleum Ultra Cover Flat Black Primer, Rustoleum's Ultra Cover Semi-Gloss White, 
Rustoleum's Metallic Finish Aluminum, and the Duplicolor Sonic Blue Pearl.

By the maker faire I had everything sanded and primed.  Unfortunately, I could not get the sound or USB Host shield to work so it was a static (but popular) display.  I eventually figured out the USB shield problems and will go over them in an electronics post.

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While it looks fine from a distance, there were some very noticeable print lines and holes in primer/filler coverage that I wasn't satisfied with.  We had a very cold and raining spring so it wasn't until almost June that I was able to get back to work on it.  I started with the dome, sanding it all the way back down and using more rounds of filler+sanding before moving on to spot putty and wet sanding.

The next photo was taken a few weeks later after sanding it back down almost to the print.

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And here it is after a couple weekends of primer, sanding, repeat...
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The aluminum eventually dulled beyond the picture above so I thought I'd give Silver Rub'n'buff a try.  It definitely did not go as planned, leaving a flat/dull appearance despite considerable efforts to buff by hand and with a machine.  It turns out I had an older batch of the stuff and although it wasn't perfect, a new tube helped a little.  As others will probably mention, a little goes a long way but I still haven't figured out how to blend the individual spots or patches.  

It's probably not super obvious but the left shoulder hub is just paint, the right side is with the rub'n'buff.

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Photo Printing the parts
Posted by: Prettyfloralbonnet - Yesterday, 02:45 PM - Forum: Prettyfloralbonnet - Replies (1)

I started printing parts back in November 2017, thinking it would be an easy finish by our local maker faire in April.  As of this post, I still have parts to print and finish.  I didn't take a huge amount of pictures as I went but perhaps I can share a few things to help others.

First off, almost everything was initially printed with eSun PLA+ white, silver, or blue.  The parts that called for it were printed with eSun ABS and my Nylon parts were printed from a MicroCenter brand.  Later, I replaced a few parts with different materials but I'll get to those later...

I used 5-minute epoxy from the local hardware store for most of my parts.

Advice: instead of clamping and gluing each part one at a time, I highly recommend fitting everything together then gluing/clamping so that rings arent' super warped or poorly fitted later on.  I had to do quite a bit of filling and even break out the orbital sander to fix places where the rings were warped or mismatched above and below.

A note about eSun's bright white: it extrudes differently than most PLA I've worked with and it appears that whatever they used to make the filament white gave it an almost chalky or softer finish which may have caused some of the cracking issues I'll mention later.

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Closer to my second maker faire (still not done), our local university makerspace purchased a Formlabs resin printer and the shop manager wanted to show off his equipment.  So, he made a deal with me on printing some resin parts.  I figured I'd try a couple detail parts for the leg/horseshoe.  These were printed at about medium quality in resin and turned out quite nice but would've cost me ~$80 if I'd printed them at their normal price.

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Fortunately, the place I work has five 3D printers including a Stratasys Dimension 1200es which prints in a proprietary ABS plastic.  It's expensive, but with the excuse of showing it off to the public as something one could do at our space, I also got a little price discount.  I used the Dimension for parts that needed to be a little tougher and have higher tolerances, such as the drive parts.  One lesson I learned is that the motor can get incredibly hot, enough so to melt the drive wheels.  I've since printed those in Nylon but won't have 'em tested until the end of October.  Also, those nylon omni-wheels have survived on concrete but they tend to pickup more hair and debris than my vacuum.  

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Posted by: Martyman - 10-12-2018, 05:38 AM - Forum: Martyman - Replies (1)

I took R2 to work today to display in our yearly Art exhibition. He was a big hit, but I think he will be better next year when he is done and "Alive". Smile

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  Width through doorways
Posted by: Martyman - 10-11-2018, 08:46 PM - Forum: Off Topic - Replies (3)

Does anyone have troubles fitting R2 through doorways?

I have just gotten my droid rolling and even without the foot shells fitted it is a really tight fit through our (admittedly 1860s) doorways. I don't think he will fit with his foot shells on.  Confused

If he doesn't fit once complete it means I will have to carry him sideways through any of the doors in our house.

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  Hi From Adelaide South Australia
Posted by: CraigO - 10-09-2018, 01:35 PM - Forum: New Members - Replies (5)

Giday all

just a quick note.  I am building an R2 for my daughter who is star wars mad.  

will need help with choosing the right electronics but I am intending at this stage to do full flashing indicators in the dome and still thinking about 2-3-2 ability.

I am printing it all on a 3 d printer so it will take a little while as there are lots of bits to print. 

I also build model aircraft so this is a distraction but a good one.

cheers all, any help is always great and happy to reciprocate.


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  body starting to come together
Posted by: phul007 - 10-03-2018, 11:07 PM - Forum: phul007 - Replies (3)

Still doing test fits but the round panels are "Nearly finished" have some more rub and buff to add to the silver.

Now its the painful task of trial fitting the triangle like panels and trimming and adding extra to make them look right.

Still a few bits and pieces for the head but getting close.

The Orange has been airbrushed after colour matching the paint using a mixture of red and yellow to create the right colour.
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  Hi from Northern Ireland
Posted by: Morbeus - 10-02-2018, 10:25 PM - Forum: New Members - Replies (1)

Hi droid builders,
I first got introduced to droid building when I went to Star Wars Celebration London in 2016.  My brother and I went to one of the panels hosted by the UK R2 Builders club and we started to think about what type of droid we would want to build.

We decided that if we were going to do this, we wanted to build a fully moving droid with as many bells and whistles as we could.  I must have spent more than a year dipping in and out of the astromech.net and astromech.info forums.  It was probably summer 2017 when I got my 3D printer (Prusa i3 Mk2s)  and over the next few months while I printed bits and pieces, the decision was made to try to 3D print an astromech droid using Michael Baddeley's plans.

I really wanted to print in ABS.  I built a good solid enclosure and sorted out most of my warping and shrinking issues.  But when it came down to it, I just couldn't stand the smell of the ABS.  Even though the printer is out in the garage and fairly well ventilated, there was enough of a smell that I just couldn't get on with.  And I reckoned I wasn't going to enjoy the experience and complete the build unless I switched to another material.  

So I'm currently printing in PLA+ (Sunlu brand from Amazon.co.uk) and starting to make some progress at last with my build.  

I'm starting with the dome first.  As I type, I've got the 6th and last main segment of the dome on the printer.  I'll update my build log as I go.

Great to finally have something recognisable  Smile

Looking forward to the journey,

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  Radar Eye
Posted by: Morbeus - 10-02-2018, 09:40 PM - Forum: Morbeus - Replies (2)

So you have to start somewhere.  I decided to start with that instantly recognisable radar eye.  

I tried a couple of different print orientations for the radar eye.  Laying it flat was OK but printing the radar eye upright, as it appears on the droid was the one I kept.
I might not have needed it, but I used auto supports in Simplify3D.  

I'm printing on a Prusa i3 Mk2s in PLA+.  I printed the radar eye at 0.1mm layer height, just to get a nice finish.  

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It turned out quite nice once I removed the supports.

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  BB8 Base nearly done and Head update
Posted by: phul007 - 09-25-2018, 10:36 PM - Forum: phul007 - Replies (5)

Still a few tweaks on the base to do with adding some protective material so it wont scratch BB-8.

Will have to print another for bb-9e not sure how I am going to change the lettering but that's a long way off at this stage.

The head is close but a few fix up on the paint is needed. The orange was created by mixing Yellow and red and then air brushing as this is as close as I can get to the original colour.

Yes that's R2's dome in the background its back in one piece but the skirt is still under repair.

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