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PostPosted: Mon Feb 12, 2007 6:45 am 
Little Foot
Little Foot

Joined: Tue Oct 11, 2005 2:03 pm
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Location: In a Galaxy Far, Far, Away!
Manta,

I'll post a new thread with Video when R2's completed....It will be a few months...... In fact it will be late June before I post it as the completed R2 will be unvailed @ MML (WSVG), Kentucky In June....I'm pushing to finish for the Cae mod contest there. Once that's done......I'll post.

It would be really cool to See Maximum Pc there as well.


CrazyBillyBob


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PostPosted: Fri Feb 16, 2007 9:19 pm 
Boy in Black
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Crazybillybob wrote:
R2 will be unvailed @ MML (WSVG), Kentucky In June....It would be really cool to See Maximum Pc there as well.
Where abouts in Kentucky? I'm trying to get out there around that time for a KCR event in Westpoint, KY.


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PostPosted: Mon Feb 19, 2007 3:03 pm 
Little Foot
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Location: In a Galaxy Far, Far, Away!
It's in Louisville Every year... Dates still not solid but their looking at the 21-24 This is based off the Kentucky Exposition Center Website...Not offical mind you (It's called the World Series of Video Games....New name but the old timers still call it Million Man Lan...MML).
Once They announce the dates, I'll post them here. Also look for a "Real" R2 Update soon, Got work done, Got some pics now I just need to sit down and write up a worklog entry and upload it all.

CrazyBillyBob

Your Humble home town Astromech Tech.
:oops:


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PostPosted: Mon Feb 19, 2007 5:13 pm 
Little Foot
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looking forward to it :)


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PostPosted: Thu Mar 01, 2007 1:41 pm 
Little Foot
Little Foot

Joined: Tue Oct 11, 2005 2:03 pm
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Location: In a Galaxy Far, Far, Away!
Holy Cow..... There's a R2SRV Update!!!!

Yep, It's Update time. Wife's been out of town for almost 3 weeks, so Me and R2 have spent allot of time together lately.

I started with installing the Rear door hinges, and getting them Aligned ...that took way longer then it should have!!!
Image

With the hinges in you need something to keep the door shut... So I installed a magnetic latch.
Image

Here's a nice view with the latch installed.
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With the rear door in I got ready to install the hinges for the front panels...I got a bit ahead of my self and removed the front skins... Only to notice that I lost part of a hinge... so I've only got one hinge for the door.
Image
I've got a few sets on order now so it ok, but there's something depressing about seeing your project go backwards.

With the hinge debacle It was time to work on something else.
As the motherboard had failed once already due to a cracked trace, I felt that the motherboard tray was probably not heavy enough for all the vibration and movement (both while driving R2 around, and in transporting him to shows). So it was time to make a new motherboard protection system. The old motherboard tray was made out of 0.062" aluminum (about 1/16) with an L bend in one end for mounting. The new "protection system" is made out of 0.152" (over 1/8") Aluminum folded into a box.
This nice sheet of Aluminum came home with me from the metal shop, all ready to protect my motherboard.
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After a little run in with the Masking tape roll, and marker the Box is laid out ready to cut.
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This stuff is tough to cut!! took 1.5 hours to cut this out on the scroll saw.
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Now comes the fun part, bending all this up. I was going into this thinking, the last one was easy to bend I mean it's only aluminum after all. Well Even with cutting 1/2 the way through with the dremel, it was 3 hours of bending for this. My home use two sections of angle iron and a vise bending was making me wish I had a nice pan break by the end.
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All you guys that have made whole cases, and mod parts with 1/8" aluminum with just a vise and some wood or metal blocks....Have my full respect now. That stuff kicked my butt, To get it into final position I tried standing on the sides of the box (mind you I'm 6'2", and clocking at 250LBS) and they still wouldn't stay. So I got out the bar clamps clamped the sides and ends in lined up so I could drill and rivet them together. After all that work, you get something like this.
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Not bad to start (I think I'll weld up the seams just to clean everything up). Now to layout and cut the hole for the Motherboard I/0, a little file work, drill holes for the MB standoffs and this is what you get.
Image
Image
The masking tape got a little beat up in the bending process but It protected the Aluminum quit nicely. I've gotta get a fan and a couple of switches from All electronics before I can finish the enclosure. I'm also planning some nice detail elements as well. I know it doesn't look like 2 weeks worth of work, but it was. I also got some planning done on my ankles, how to attach them and how to make the middle one. As well as a new light source for my projector (remember that old Idea...Yep it's back too!)
I'm looking at the end press here I'm starting my push for MML6... So keep watching for more fun!

CrazyBillyBob


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PostPosted: Thu Mar 01, 2007 11:36 pm 
8086
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Joined: Tue Sep 13, 2005 7:20 pm
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Amazing...Simply AMAZING !!!!

Cant wait to see the end result.


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 Post subject:
PostPosted: Thu Mar 15, 2007 6:49 am 
Little Foot
Little Foot

Joined: Tue Oct 11, 2005 2:03 pm
Posts: 184
Location: In a Galaxy Far, Far, Away!
Ok, Little update on things here in the AstromechLab..

I worked on the center ankle cover, Not structural just hides all the load bearing members.
I skipped pics of the layout (figured you got the Idea by now :) )
Here is all the pieces laid out, The large one at the top will be folded into a rectangle, the flat area's on the curves at the bottom are just setting there to show what they should look like (test fit).
Image

Then we fast forward through several hours of bending, welding, grinding to get this, still not done the flaps on the bottom need bent into place and welded. I'll use a series of tack welds to hold them into place while bending them from bottom to top. After there bent I'll finish the weld. The Mig welder makes this so much easier and faster then my torches.
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With all the welds in place and cleaned up, it's time for a test fit.
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You notice that it doesn't go all the way down, the corner of the load bearing member (alum plate in the middle) needs trimmed down... It will need to meet the grinder again. Other then that it looks good.

Next we'll move to the Fan Guard for the 40mm fan that will move air into the Processor protection System (little Alum box that the motherboard hides in). I had several designs that I had trouble picking from but finally settled on this one. Nice R2 Logo with 45degree connections to the screw mount holes (Thanks Grunts!!)
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The drawing is spray glue mounted on a scrap piece left over from making the protection system, 1/8" alum taped to keep it from scratching. The quarter is there to show you how big a 40mm fan really is. After an hour or so meeting with the scroll saw, this lovely little thing emerges.
Image
Needs some clean up with the needle files, and a bit of sand paper (yes I know the paper's still glued on...I'll get to that). Well there's a bit of a problem, see the idiot that drew the fan layout, mismeasured the screw mounting holes...
Image
So they don't line up so well, It's useable but not perfect...So I'll be making a new one.....That's why the paper's still on, keep you all wondering how shinny is it really under there??? Well you'll have to wait till next time :)

From the deep bowels of a sand crawler, right next the scrap heap....
CrazyBillyBob


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PostPosted: Thu Mar 15, 2007 7:43 am 
Monkey Federation (Top 10)*
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Crazybillybob wrote:
So they don't line up so well, It's useable but not perfect...So I'll be making a new one.....That's why the paper's still on, keep you all wondering how shinny is it really under there??? Well you'll have to wait till next time :)


Can you torch them into shape?


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PostPosted: Thu Mar 15, 2007 8:49 am 
Little Foot
Little Foot

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Location: In a Galaxy Far, Far, Away!
I probibly could bend them into position, but it wouldn't look the way I really wanted, I could use as is just use smaller Screws.... I've not skimped on Quaility yet, why start now...Just call me anal!

Crazybillybob


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PostPosted: Sat Mar 24, 2007 5:46 pm 
Little Foot
Little Foot

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Location: In a Galaxy Far, Far, Away!
I've got a question for everyone (ok mainly Maximum PC staff, but others can chime in too) I was flipping through "Another PC mag" this week checking out there rig of the month (or what ever they call it) and noticed a blurb about submitting your rig for concideration.... It basicly stated that if it didn't look like a pc (IE. box shaped) don't bother sending it....
as a modder who likes making non-box shaped rigs... I've gotta ask the question Is it harderd judgeing the non box rigs ? now I know that maximum PC doesn't do this so that's why I've asked you...you have experiance looking over both, what makes a rig stand out....

as allways if this post would be better suited for another thread or section please move it (just let me know where it went :) )

Thank you,
CrazyBillyBob

(oh, and I'm not planning on flipping through that other rag anytime soon... Squares just disapoint me!!)



Remember folks MML6 is June 21-24, 2007 In Louisville KY.
BYOC, tournements and a fun time. Check Lanwar.com for more..I'll see you there (R2 as well)


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 Post subject:
PostPosted: Mon Mar 26, 2007 8:12 am 
Monkey Federation (Top 10)*
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Hey do0d, copy that entire post, and create a new thread in the magazine feedback folder. That will get their attention. :D


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PostPosted: Wed Apr 04, 2007 9:50 am 
Little Foot
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I was out of town for a bit (work), so now I'm back and I'll show you what I've gotten done over the last week or so.
I started by mounting outer ankle covers (added just a little more metal to fill in some voids)
Image

With those mounted I focused in on the Center ankle, for it to be mounted I had to cut a recess in the bottom of the frame (about 1/4" of wood was removed from the 3/4" plywood), also I filled the area around the perimeter full of expanding foam ( the .04" styrene was sagging allot, and any bump made it flex). Then the Ankle over was pop riveted into place.
Sorry, It was getting ready to rain when I did the cutting and mounting, so I was in a hurry and forgot to snap pics till I was done.
Image

I also gave in and ordered a 24 contact Slipring (straight from China...that was fun). The Slip ring allows electrical connections to remain constant even when the parts are spinning. With 2Amps max per trace I'll end up using about 21 of the 24 contact straight out of the box, this and signal to noise ratio is why I gave up on building my own.
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This thing has nice gold contacts inside, so I can run that USB web cam through it :) and some Serial communication to the logics up there. To make removing the dome less of an issue I attached a DB25 to one side of the slipring.
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Getting all these wires hooked up and tested is an on going process so exspect to see more of it soon.
I also recut that Fan guard that I messed up, took way less time this go. Still need to file the saw marks out and make it all purrdy but it's getting there.
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While I was cutting stuff I took a few minutes to cut a lid out for the Motherboard protection system....Nothing fancy...
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We all know that R2-D2 makes sounds, Well So will R2-SRV to do that we need Speakers, well the speakers need mounts that was the next task tackled. I got 1 cut out of 18gauge steel that I have...This stuff is tough to cut with a scroll saw (inside cut can't be done easily with tin snips).
Image
Looks nice, Lets test fit it with the speaker.
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Now that I know it really fits, I'll drill the holes in the corners for mounting screws and cut out the second one.

I've got a bit more fab to finish up, I think I'm down to 6-10 parts left to make, and mount the front doors and we're ready for paint (ok,I know I still need to make the Mp3 player work, and mount the projector, and make the 12V battery charger but this can be worked on when the paints wet....I'm trying to schedule it all) Plus with g00se's I7 threating to be at MML too, I need to kick it up a notch ( what, I love the idea of I7 and R2 Racing at MML....any betters out there???) (G00se's work log is at Gruntville.com)

Please let me know what you think. I also know it's been a long time since I posted a pic of the complete R2 (or at least everything I've got done)... That's coming, I'll post one before paint, then I'll post one after we get to MML when the paint's done...what can't reveal everything too early.

CrazyBillyBob


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PostPosted: Wed Apr 18, 2007 5:46 pm 
Little Foot
Little Foot

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Location: In a Galaxy Far, Far, Away!
Welcome once again to This old Droid.....
This week we'll get a glimpse of one of the last steel details as it's starting. We'll also make an astablemultivibrator.... Fun! Also there will be a revisit to the motherboard protection system.. Now lets go to the shop.

I've been working on finishing up the fab of all the steel details (so the welder can be switched over to Aluminum welding), I'm down to the last 4 it's really just 4 of the same part, It's a detail on the side of the foot. Here's what I've got done (still more work needed) It's just the face plate.
Image
There will be more work completed on this part this week.
Most of my time was spent working on the more "Fun" part, the lighting.
Their is a yellow/ green oscillating light on the back of the dome. For that I made an astablemultivibrator circuit (big name little circuit, has 2 transistors, 2 capacitors, and 4 resistors in it) a home made PCB makes it a nice little package (the LEDs in the picture are 3mm in Dia)
Image
With the board made and soldered up, I needed some thing to house it.
Image
The white PVC plumbing fittings help space the lights away from the plexi lens in the dome (just a piece of lexan lightly wet sanded 800grit inside and out) so that there are no hot (bright) spots on the lens. Here's what this crazy thing looks like assembled.
Image
When mounted in the dome you get an effect like this Video of Lights running in the dome! (file is about 17Mb)
Now I know that you've seen the front logic displays but here's a video of them in action Video of Front Logics running in the dome!

Now that I'm done showing off the eye candy, lets see what’s up with the Motherboard protection system.
The power / reset switches are test fitted in the enclosure (you can also see the holes for the Wireless network adapters antenna near the bottom right corner).
Image
Also the Fan hole has been drilled.
Image
I know I know you want to see that Sweet R2 Fan guard mounted over that hole..... OK, stop twisting my arm! :)
Image

That's where I'm at currently, got allot of work to complete and no time to do it! so keep watching I think it's going to get fun around here!


CrazyBillyBob


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 Post subject:
PostPosted: Mon Apr 23, 2007 5:57 am 
Little Foot
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Joined: Wed Oct 18, 2006 8:29 pm
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Location: Denver
Awesome amount of work. :D


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PostPosted: Tue May 15, 2007 6:47 am 
Little Foot
Little Foot

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Location: In a Galaxy Far, Far, Away!
Spurred along by G00se's I7W7 progress, and the impending Droid Race at MML, It's time for a little update
The Half-moon details for the feet are finally fully welded.
Image

The half-moon details will be mounted on the sides of the feet Like this (minus the hand ;) )
Image
Just need to drill a couple holes in the foot for mounting.

With that done all of the large pieces are fabbed... I can finish mounting things and start the painting process.

For Painting all of the wood parts get a thin coat of bondo, and/or glazing putty, This hides the wood grain and gives me a smooth surface to paint on.
Image
Here you can see one arm coated in putty the other has been primed and sanded, afew spots have been filled in again....Rinse and repeat!

Image
The booster covers here have been puttied, sanded and primed. The one on the left is all ready for paint, the one on the right needs a few last details glued on and some spots fixed and a few more coats of primer.

While the paint was drying (no I didn't watch it much this time!) The Slip ring was mounted into the frame.
Image

I also started getting the Dome Motor ready to install, It's out of the automatic seat belt that was in my wife's car. Don't worry she doesn't drive it anymore......My Mother in law does :)

Image

I've also been working on some more of the Electronics, no fun pics just designs and what not. Also a few projects around the house, and the fact that I've gotten a new job, back in Ohio that I start soon (about 5.5 hours from home) have kept me busy. I'll be hitting R2 hard for the next few weeks as I have some time off coming...
As always let me know what you think.

CrazyBillyBob


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PostPosted: Tue May 15, 2007 8:32 am 
Monkey Federation (Top 10)*
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Do0d,

You where right when you said this project was never going to be finished! lol


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PostPosted: Thu Aug 09, 2007 10:42 am 
Little Foot
Little Foot

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Posts: 184
Location: In a Galaxy Far, Far, Away!
What's This an Update??? :?: :shock:

Nope, just a little Text Update, Down Boys down!!!

Just wanted to Pimp Showdown Lan 2007 --> INDY!

I will be there with R2SRV and My Buddy will be there with our ATM Server! (so we may need 4 or 5 guys to help us unload :)) )

If you missed the banners and Side Bars (or Front page Exposure) here On MaximumPC.com I'll list the important stuff.
When : September 14-16
Where: Indianapolis, Indiana Convention center (RCA Dome)
What: A 500 user LAN Party, With Case mod contest, Free stuff, and gaming tournaments.
Cost: $40 (Well worth the cash!!!)


I'll be seated in 7M but I'm sure you'll See R2 All over the event (or the sidewalk out front :) )


If your a MaximumPC Staffer (and Can Prove it.... :lol: ) Let me know We'll work out a you can Drive me session for you (If you've always wanted to Drive R2, here's your chance!).


CrazyBillyBob

Ps. I'll have a new update....Yes with Pics Very soon. Just been out of Town for work Allot !


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PostPosted: Thu Aug 09, 2007 11:11 am 
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Crazybillybob wrote:
If your a MaximumPC Staffer (and Can Prove it.... :lol: ) Let me know We'll work out a you can Drive me session for you (If you've always wanted to Drive R2, here's your chance!).



Can I take him out onto the brickyard??

Seriously, good luck with the mod contest.


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PostPosted: Thu Aug 09, 2007 12:40 pm 
Little Foot
Little Foot

Joined: Tue Oct 11, 2005 2:03 pm
Posts: 184
Location: In a Galaxy Far, Far, Away!
TobyKY76 wrote:
Crazybillybob wrote:
If your a MaximumPC Staffer (and Can Prove it.... :lol: ) Let me know We'll work out a you can Drive me session for you (If you've always wanted to Drive R2, here's your chance!).



Can I take him out onto the brickyard??

Seriously, good luck with the mod contest.


If we can Get access I'd be all for it (that would be some SWEET Photos!)


CrazyBillyBob


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PostPosted: Thu Aug 16, 2007 7:46 pm 
Little Foot
Little Foot

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Posts: 184
Location: In a Galaxy Far, Far, Away!
What??? An Update..... About Time!!! :)

It's been a while since I got around to posting an update so some of this is a bit dated, but you all have stuck with me this far I'll not start skimping out now!

The first group here is the end of the mad dash to MML this year.

The Big thing was the Paint Job on the body, Legs, and feet.
To start it off I masked off the inside of the droid shell.
Image
Image

Once everything was masked off the painting started... After 2 and 1/2 cans of Krylon fusion (and a few hours of drying time) R2's body looks...well white (it's not really white, it's a bit offwhite but the camera adjusts to make it look white)
Image

I also found some Great stuff for cases, It's Cheap, looks good and holds paint well... What is this miracle stuff?
Image
That's right Aluminum window screen.

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This one layer painted and cut to size.

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Here's 2 layers of screen glued to the back of the aluminum grill cover. My two Speakers are mounted behind the grills one on each side of the droid's body. I can see this stuff showing up in some of my other mods where I would have used moders mesh before.

Then there's the night before MML (we took off @ 3am Thursday...I didn't sleep at all that night)
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This was what the inside of my friend Cytog's garage looked like till about 2:59am :)

There was also some work completed at MML (some Wireing finished..and some repairs from shipping damage)
Image
Target Practice Is lending a helping hand here too.

At this point your thinking WHY!!!
Well here's a few pics from MML6, all I can say is that Running R2 around in a crowd is FUN!!
Image
R2's first kiss.
Image
Some Jedi younglings and their Masters.
Image
Then there's always the Grunts :)
Image
There's also the Droid Races too!

(a special thanks to Cytog... the last few pics were taken by him)

Well after recovering from MML6 I started the push to Finish the last remaining things on R2-SRV In preparation for Showdown LAN 2007 - Indy . Sept. 14-16 2007. The biggest thing not done now is the Dome Rotation.
The first step to getting the dome to rotate is to get the drive wheel mounted on the motor shaft.....

For that you need a shaft adapter (a chunk of metal that is as big around as the hole in the middle of the drive wheel and has a hole in it as big as the motor shaft) how do you get one of these? Well I took a Brass Blank about 1.5 inches around
Image
Added a little Lathe (8x12" model)
Image
Then add in a bored 55 year old father (recovering from a kidney removal) .... Sorry the Old guy is camera shy :)
Mix all that up and leave for work one morning.... When you get home some 8-9 hours later... you have a bored 55 year old guy with this in his hands
Image

With a little work (drilling and taping a setscrew hole) and mounting the wheel you get this ...
Image

Then your company sends you to Texas for 10 days....30 days later I'm still here So I've gotten nothing more done :( But the up side you all will get more R2-Srv updates in the future! (hay, act more excited!!)


Time to pack and hope my flight home is not delayed!!

CrazyBillyBob


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