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Scratch Build – In Progress Project: R2-D2 (on a low budget)

Discussion in 'Project Logs' started by Frenkie, 29 Feb 2008.

  1. Frenkie

    Frenkie Lets mod the world!

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    [​IMG]

    Project: R2-D2

    This is the worklog of my R2-D2 casemod, which is an ultra-low budget project.
    So far I have spend about 120 dollars on it. Let me show you how I did it.
    Basis of this mod is a written-off garbage can that I was told to get rid of. From the internet I gathered pictures of R2, and started my first dremel-cuts, based upon guessing the size*.
    I am making this mod in three big chunks; the Dome, the Body and the Legs. I am building all three simultaneously, so I’ll be jumping from one to another all the time.

    Body.
    The base, an old garbage can, about to be thrown away.

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    Let’s get an old PC case from the attic.

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    Quickly disassembled.

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    And what is left over, a mobo tray and a backplane.

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    Hmm, a bit too big. Got to make that a bit smaller.

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    From the many pictures of the net, I estimated the length-width ratio, and decided to cut off a big
    chunk. I used this pneumatic tool, sort-off giant air dremel.

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    For all you starting casemodders; always wear eye protection. Trust me.

    Also used some ear protection, as the bin was working as a drum.

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    That’s off, now the sharp edges.

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    Let’s try the tray. I see I have to fold the edges.

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    -----------------------------------------------------------------------------------------------------
    *let me get back to that guessing part. áfter I started, then I came upon Astromech and the guys
    from the R2-builders club. They kindly provided me with the original blueprints of the real R2. I
    found out, my R2 was 75% of the real deal. Also the blueprints were in inches. So now I am
    constantly recalculating the blueprint to 75 % and then from inches to millimeters. :)
    -----------------------------------------------------------------------------------------------------
    The back, looking good.

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    For use as "vents" I dug up these ancient ( 1984 ) grills from speaker boxes.

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    Used the dremel to cut the hole for the vent.

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    Later on, I see the vents don't stick out at all. I made a small container to hold the fans.
    I made it from Vikureen
    which is a polystyrene.

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    My sponsor SpacePromotion provided me with two 60
    mm fans with white LEDs. ( No, It will still be low-budget, not because I get a lot sponsored )

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    Hmm... that doesn’t fit because of the extra wires for those LEDs.

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    Bit of creative cutting.

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    Last edited: 29 Feb 2008
  2. Scirocco

    Scirocco Boobs, I have them, you lose.

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    Nice start there. And let me be the first to say: May the Force be with you! ;)
     
  3. -Nick-

    -Nick- New Member

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    haha excellent idea, keep it up (Y)
     
  4. iwog

    iwog Linux cursed

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    hmmm this looks interesting, lets follow this one.
     
  5. Frenkie

    Frenkie Lets mod the world!

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    Thanks guys, I am sure that even non-star wars fans ( yes there such people ! )
    won't be disappointed at the end. Let's continue with the next part:

    LEGS.

    A stack of MDF wood and some wood-glue.

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    Something like this.

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    First cuts.

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    Using the workmate and clamps the legs are taking form.

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    With some sanding they look now like this.

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    Starting chapter three; the DOME

    The garbage bin lid. With the help of the R2-builders blueprints I measured the different panels.

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    Good hard stainless steel, nice to cut with the dremel.

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    First hole is in; this one is for the RADAR-EYE.

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    And these two for the FRONT-DISPLAYS.

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    Here with the blueprints, this is very tricky as the measurements are not in inches
    but in degrees, minutes and seconds. :(

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    Back to chapter one, the BODY

    On the bottom, there should come a "skirt". I made it from MDF wood.

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    First try with a rope and a nail......

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    -sorry, one photo missing here-

    OOPS, miscalculated! Not 26 cm in diameter, but only 21. ( yes I forgot the 75 %)

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    The skirt sides.

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    After this I hollowed out the massive disc and cut out room for two mini CCLs.

    Made several holes in it with a milling machine. ( mill ? )

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    Shopping time. Here you see a few mini table stands, two circuits from Velleman,
    spraycans, blue pinstriping and some spectacle glasses.

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    More MDF and some aluminum for the support frame.

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    Something like this.

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    Fitting in the case,

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    Bolted to the bottom.

    [​IMG]
     
  6. Xtrafresh

    Xtrafresh It never hurts to help

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    lol, looking at the bin, i can see why you picked r2d2 as a theme :D

    Keep going mate, we are lurking, looking lovin it and still not posting :)
     
  7. Frenkie

    Frenkie Lets mod the world!

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    Thanx!

    Made a Rader-eye holder from some MDF.

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    Round it off and fitted the eye glass.

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    For the two Front-displays I bought two Velleman circuits, originally with red
    LEDs, but I won’t be using those. Instead I bought in Hong Kong a few hundred
    blue and white LEDs for 0.99 Euro per 100 )

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    Also from Hong Kong comes this el cheapo xmass lights, 100 white LEDs and
    8 different modes.
    Cost 0.99 Euro.

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    A small mini-lava lamp, cost 0.99 euro.....

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    It contains a micro circuit that fades three LEDs in and out.

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    From Vikureen I made a small container to attach it to R2.

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    The guys at Space Promotion gave me this
    ZALMAN fancontroller.

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    A rectangular box into a round case...hmm I have to think of some innovation support brackets.

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    From a lot of debris I made several little thingamajigs to give the legs more detail.

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    Doesn’t look too bad.

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    To attach the ankle-cylinders I screwed in a woodscrew and cut the head of it.

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    Glue it with construction glue.

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    And there it is.

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    On the back a larger display, I used some PVC and cut grooves into it to help me
    bend it with the curves of the dome.

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    Pre-drilled the LED holes.

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    Bended it with a heatgun until it matched the curves.

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    Then drilled the final 5 mm for the LEDs.

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    Attached a few LEDs, then glued them on and waited 24 hours before I attached the next batch.

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    All LEDs in and glued.

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    Quite a mess eh ?

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    Because it is originally white and blue, I made some blue transparent stickers.

    [​IMG]
     
    Last edited: 3 Mar 2008
  8. Colossous

    Colossous Member

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    Great project - loving the improvisation - Xmas tree lights Cheesecake :D
     
  9. 500mph

    500mph The Right man in the Wrong place

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    Thats quite a mess, but it looks worth it.
     
  10. InSanCen

    InSanCen Buckling Spring Fetishist

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    Loving the Ghetto cheapness, but with the good results.

    Will watch this one.

    Good luck!
     
  11. Frenkie

    Frenkie Lets mod the world!

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    Made some strips of Vikureen for the rectangle parts that come into the round outer layer.

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    Neatly follow the lines and break it off. ( the plastic, not the scalpel )

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    Also from Space Promotion i got these
    Zalman harddisk coolers.

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    At first I wanted to mount them on the bottom.

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    Then decided to mount them as high as possible.

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    Dremel dremel dremel..... A hole!

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    The supports are the same as for
    theZalman
    fan controller
    . ( type QeD ;) )

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    Preparing the table legs for mounting.

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    Screw them on.

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    An old cylinder that used to contain wire.

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    Cut in half and measured it.

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    Cut out a small piece where the table leg is coming out.

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    Spray painted the dome and radar-eye holder.

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    For use as a holoprojecter I got this antique webcam, gave it a spray as well.

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    made a hole and glued it on.

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    From the front.

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    An old circuit I use to fill the gaping hole on the back.

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    I had plenty of LEDs to spare to I drilled holes in it @ random.

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    Glued it inside the dome with some quick and dirty supports.

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    Started to glue the LEDs into it.

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    When it is on, it glows and tingles a bit like this.

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    With Gelly Roll pen's I colored the circuit a bit. With regular light you don’t see anything...

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    .....but with some UV on it..... :)

    [​IMG]
     
  12. Yemerich

    Yemerich I can has PERSUADETRON?

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    wow! that is surely an ambitious project wich is coming up VERY nicely. The low budget is giving u lots of good ideas for improvization.
    Very nicely done. Anxious to see the rest :)

    ooo, very well documented BTW :)
     
  13. sethnmalice

    sethnmalice New Member

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    Very impressive cheap mod,
     
  14. mutznutz

    mutznutz Cos Ive got a beard u label me evil

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    Looking good that congrats
     
  15. ROB 636

    ROB 636 Ski-Ba-Bop-Ba-Dop-Bop

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    I like the UV ink on the board.
     
  16. rambo

    rambo New Member

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    HOLY F*CK that looks realy nice i like R2D2 so i wnat to see how close you can come.
    keep it up ,rambo :dremel:
     
  17. Jipa

    Jipa Avoiding the "I guess.." since 2004

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    What is it with people suddenly making loads of cool mods! Good job, gotta love cheap mods with loads of innovative details.
     
  18. JesterQ

    JesterQ New Member

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    this looks really good . and cheap too !
     
  19. rodeo45

    rodeo45 Who's your daddy ???

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    That looks cool! Specially that old circuit with UV pen lines on it - WOOW!! Great idea!
     
  20. craigbru

    craigbru Now... with more CNC!

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    Wow, this looks amazing. You've got some real ingenuity here.
     

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