Since we don't have a DIY subforum anymore, I'm building a styrene droid. So this is where I'll share what I'm doing. I've never built one of these, but my son really wanted to make a robot together, so I figured go big - or go home - let's make a droid.
I'm going to try for 100% plastics and foam to keep the weight down, but we'll see where it winds up. The motor mounts in the legs will likely be aluminum to keep them from breaking. I'm not super electrically inclined when it comes to people who make the droids make sounds and such, or have different programs, so if when I'm done he rolls by remote control, and his head spins, then I'll consider that a great step 1, and leave plenty of room in the body to make the arms work and everything else later.
So I'm making C1-10p or "Chopper" from Star Wars Rebels. I changed it a little bit as I was building so it's not "screen accurate" but he'll still look good I hope.
[IMG]http://www.disneyme.com/sites/default/files/star-wars-rebels/characters/chopper/SW_CI_rebels_chopper.jpg[/IMG]
So here's where I'm at so far.
I ordered a lot of different styrene sheets from an industrial plastic supply co.
There's 1/8" and 1/32" that the droid is mostly comprised of.
I started off by making 3 horizontal frames. They are essentially 18" wide circles, with 6" flat spots for the legs to sweep by out of 1/8" styrene.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160420_200125224_zpshshl74be.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160420_200125224_zpshshl74be.jpg[/IMG][/URL]
Then I made 9" uprights to frame the various missing panels that are on the body, and to help the structure stay ridgid.
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On the second level I also used 9" uprights and also split the front center to allow for the upper section to house a utility arm. I didn't use too many measurements from the stock info available online and mostly just went for a "this looks right" compared to a bunch of photo stills.I also found a few in progress builds to gauge scale and draw panels and such.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160421_120845170_zpsw2xjezb7.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160421_120845170_zpsw2xjezb7.jpg[/IMG][/URL]
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I wrapped the front with the 1/32" skin, and trimmed it to fit, then marked the spots for it to get cut out. Then adhered it to the frame. The back I do not have on yet. I want to make it removable to put the batteries and electronics in the body. So I'm still thinking of how I want that to happen.
Where I'm at now is - working on the head. But also I cut out a lot of individual parts of 1/32" styrene to make the various panels and details for the front skin.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160421_143645645_zps53yudaam.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160421_143645645_zps53yudaam.jpg[/IMG][/URL]
That's the progress so far.
Well, I went out to the hardware store because I just couldn't wait to keep working, and I had to solve how the legs were going to mount before I did anything else to the body.
I drilled a 1 1/4" hole on both sides of the body on the flat leg mounting sections. I figured I'd put the strain on a rod instead of the thin sides. So I put a 1" pvc tube through the whole body, and capped it with two 1 1/4" x 1 1/2" adapters on both sides. These will actually mount in the legs.
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[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160421_200834748_zpsmvi9kust.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160421_200834748_zpsmvi9kust.jpg[/IMG][/URL]
For the legs I looked at a few designs and drawings with measurements and came up with a base pattern for the back of the main leg portion, which will also mount the wheel housings at the bottom. I also found a nice looking caster for the center leg, but more on that when I get to it. Once I had the back of the legs cut out of 1/32" styrene, I cut out an identical piece of 2" foam, then glued the styrene to the foam.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160421_202116836_zpswwhkd0dt.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160421_202116836_zpswwhkd0dt.jpg[/IMG][/URL]
The whole goal mainly of this build is to keep it lightweight so that I can move it around myself if needed.
I built a "front" section for one of the legs. Chopper is made of multiple droids basically, so his legs are not identical. One is smoother and more aerodynamic - but grey and ugly, while the other is newer, white, and more geometrically flat. This leg is the smooth and ugly one. I knifed the foam to match both sides of the patterns so it was angled, so the front and back are plastic, core is foam, and the sides will be plastered, and bondo'd sparingly.
Tomorrow I'll sand it and do small amounts of body filler if needed, but trying to not put a lot of it as it's heavy. Right now the plaster is drying (not pictured)
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160421_204834446_zpsfq9ojb3d.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160421_204834446_zpsfq9ojb3d.jpg[/IMG][/URL]
This is just the main section of the leg.
Dad of the year award goes to...
Well, I got the head about 75% together now. It just needs a top skin once I fill in the gaps where I cut the upper ring too small.
I tried a styrafoam frame and just making a plastic frame and neither worked. The trick was to input the measurements I wanted into a t.cone generating program that i had to download - just told it I wanted a 19" bottom, 15" top, and 8" high and it generated the two arcs for me, which I patterned and cut out, then I laid out the sensor arrays that go in. One is a 2" end cap, the other 2 are 1.5" end caps all PVC. The larger one I'm going to put some kind of lens in in the future. But for now it's painted black. They're just pressure fit into the skin for now.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160422_155401194_zpsgxdris2m.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160422_155401194_zpsgxdris2m.jpg[/IMG][/URL]
After I had the skin, I glued both halves together with a splicing joint on the bottom made out of some more styrene, and utilized the two "door" openings for a sandwich effect to really hold it all.
Then I taped the cone to the bottom 19" plate I cut out of 1/8" styrene.
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Afterwards I built several 1/8" uprights to help keep the cone's shape then glued them all in, drilled a 1 1/4" hole through the center for my pvc centering bearing axis that the head will rotate on. The head will also be supported on wheels eventually.
Then it got capped with a ring that the top skin will screw to so it is removable.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160422_185321421_zpsa5l8codz.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160422_185321421_zpsa5l8codz.jpg[/IMG][/URL]
So the legs were a complete failure. As it turns out - styrene and expanded styrene (styrofoam) are two completely different substrates so the glue that bonds one, does not bond the other, so the styrofoam literally melted inside of the styrene and plaster of paris sheathing. So... I'll have to go to MDF and carve the legs, which will work the same way - I'll have to put filler on it so it doesn't look porous, but it will also be way more robust, and probably better in the long run. So since my son was gone at his mom's today, I thought it would be cool to surprise him when he got back tomorrow by adding a little color. He's 3 so trust me this will be awesome.
I painted with a few different grays, whites, and tans first on the body, then orange on the head. Then I went for all the acrylics i use to paint my miniatures and made him dirty. He's a little more dirty and wrecked than in the cartoon, but it still looks the part I think.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160423_232146338_zpsabyluxrc.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160423_232146338_zpsabyluxrc.jpg[/IMG][/URL]
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I'm also going to add 4 pine uprights inside the body to screw the rear skin to so that it's removable, and then set 4 up front as well to increase rigidity and have a base to set the 12v batteries on for the drive legs.
They'll be driven by 12v scooter motors with belt drives. THe head will be driven by a smaller belt drive motor, and the front utility arm will be on some kind of servo that throws the arm forward, then retracts it.
Then I need to find rollers, or bearings, or even skateboard wheels to put between the head and body so it spins nicely.
Oh damn, that weathering looks superb, Serj.
Thank you.
Today I put the last little Greeblies into the empty open panels. Then I painted them. I also assembled an arm out of two couch legs, some PVC, and some more styrene plastic, then mounted it to a wood base so it swivels. I'll have a rod on it that push it in and out with a servo in the body. Not terribly exciting, but it'll be something. I also need to do more research into the actual RC stuff. I'm looking at a lot of information and getting a bit overwhelmed. I basically want it to be as simple as possible, and ordered 2 (3 channel each) receivers, both at 2.4ghz thinking 6 sets should allow for the movements. I need a tractor/tank setup, so each wheel motor will roll forward and back, the head will be on a third motor roller going left and right, then the arm to go in and out with a servo. Besides those pieces, I am not really sure what else to do, I feel as though there's some kind of control module necessary.
Anyway, here's what happened today.
[IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160424_135701499_zpsfqxibnyh.jpg[/IMG]
I also cut four holes in the "neck" area to support three closet rollers to some uprights in the body that the head sits on to rotate. They work awesomely with a little bit of resistance so the head won't be too fast. I am going to use an 80rpm motor with a reduction gear and a rubber tire to roll the head from the body. The fourth unused hole is for the drive wheel. The center is just the bearing for the head axle.
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[IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160424_160818951_zpsseanzoxb.jpg[/IMG]
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oh, looks superb the attached photos. I will wait for more updates here.
Man, this is something that I'd honestly love to get into. This shit looks so rad, but I'm not sure where I'd start.
the astromech builder's club has a host of information. But if you dont DIY it, it can easily cost $5,000 to build a proper one. This one im at about $300
Well, the droid's up on legs now. I built some new frames out of plywood, and the feet which will house the motors and some wheels off a large RC buggy.
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Styrene plastic is cool to work with, as it takes minimal framing to make a shape you want. This is going to be the "clean" and white/ blue leg as Chopper is a mix of several different astromech parts. His other leg is ratty and green and totally a different model, but the frames are exactly the same so he stands upright the way he should instead of leaning over one way or the other.
This leg is almost done, just a few more details and the "hydraulic actuators" added.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160428_215027053_zpsrgfzon5u.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160428_215027053_zpsrgfzon5u.jpg[/IMG][/URL]
I also have to tilt the front caster more forward on a wedge or something, as it hangs too central on the body, even though it's mounted at the front of the underskirt.
Wow, truly incredible. it really amazes me how good some people are at some things and how everyone is better at everything than me
You really have a talent for just making something out of nothing. It's really impressive how well thought out that is and how good it looks. Good job!
I wish I could make things like this.
Almost kinda ready for MAy the 4th.
I need to find some kind of plate for the antenna, so right now it's just a pvc pole sticking up. It's spposed to have a ring around it about 2" above his head.
He is on wheels now that are in the feet. They are made of the front turning wheels of a RCbuggy. They hold the weight perfectly. RIght now I'm pretty sure he's about 30lbs. The junk leg is also a bit heavier than the cleaner leg, so I filled it with some foam and other stuff to try and bring the mass up so he won't drive slower on one side than the other.
Here's where I'm at though.
[URL=http://s43.photobucket.com/user/serj22/media/IMG_20160429_180647544_zpszjj4vh7w.jpg.html][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160429_180647544_zpszjj4vh7w.jpg[/IMG][/URL]
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And with some paint and the outer skin added:
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Also the diameter on the antenna is bothering me so I may replace it with a periscope eye for now, similar to the one R2D2 had when he fell in the swamp.
On another note, I ordered some receivers and they look totally wrong for what I want to do. But I also have no idea what I'm doing. IS there someone on the forums that could help me design a system that will work as simply as possible?
This is what I need to drive:
3 electric motors, forward and reverse operation, and speed control
1 servo, forward and reverse.
It would be awesome if I could do onboard sound as well, that is also radio control and plays random files or something. But Again, no clue what I'm doing. So whatever parts i need, etc... I have no idea.
[quote][IMG]http://i43.photobucket.com/albums/e356/serj22/IMG_20160430_220657578_zps890miz45.jpg[/IMG][/quote]
So [I]that's[/I] where my missing dinner plate went!
[QUOTE=ToastedBread;50246310]So [I]that's[/I] where my missing dinner plate went![/QUOTE]
It's actually a decorative charger from Michael's. You know the fancy plates you put under your actual plate to be fancy? it also says "do not eat off this plate" because it had crappy paint that literally peeled off the second I drilled a giant hole in it.
Do you think you could file or sand the edges on it to be a little harsher? It's got such smooth contours compared to the entire rest of the droid that it looks really out of place.
[QUOTE=Serj22;50246526]It's actually a decorative charger from Michael's. You know the fancy plates you put under your actual plate to be fancy?[/QUOTE]
Ah yes, one of the few things I remember from the fancy dining portion of my 9th grade life skills class 7 years ago. :v
[QUOTE=Trekintosh;50246576]Do you think you could file or sand the edges on it to be a little harsher? It's got such smooth contours compared to the entire rest of the droid that it looks really out of place.[/QUOTE]
The plate you mean? Yeah I agree. Also, it looks like a plate. I thought for sure it'd just look right and fit in, but just like you're saying - it doesn't. Unfortunately I'm out of 1/8" plastic. I'll see what else I can find maybe.
For now, Chopper is hanging out at my Brother's comic shop. He was around for May the 4th and a few people were taking pictures with him. He'll probably stay till after free comic book day then I'll do some RC work and more detais.
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That´s top grade work, but the only nitpick I have is that the antenna seems to have a bit too much diameter.
[QUOTE=Ctrl;50270313]That´s top grade work, but the only nitpick I have is that the antenna seems to have a bit too much diameter.[/QUOTE]
I have the same nitpick with it. Don't worry.
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