1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

Scratch Build – Complete Robocop Casemod - ED-209 by RandomDesign

Discussion in 'Project Logs' started by random2k4, 1 Sep 2023.

  1. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    And now for another mod.
    I worked together with the company Nacon to create a mod that
    should promot the upcoming Robocop game. So I decided to build the ED-209 from the original movie.

    The mod already was shown at gamescom. Unfortunately only in the business area.
    Now I got some time to finish the rest of the work and start the worklog already.

    I got some renderings from the video game.

    [​IMG]

    [​IMG]


    I took them as a reference to creat my own version of the ED-209. Many parts will be 3D printed,
    but others will be molded and cast in resin.

    [​IMG]

    [​IMG]

    [​IMG]


    Cause this specific version will be raffled away, my wife got the idea to directly build a version 2.0
    once this project here is done. Already got a long list with improvements and changes I want to make to this one.

    But first lets finish version 1.0 :)
     
  2. Monkey Puzzle

    Monkey Puzzle Minimodder

    Joined:
    18 Feb 2009
    Posts:
    351
    Likes Received:
    153
    "I think you better do what she says Mr Kinney."

    Looking forward to this. Nice modelling!
     
    random2k4 likes this.
  3. Vault-Tec

    Vault-Tec Green Plastic Watering Can

    Joined:
    30 Aug 2015
    Posts:
    15,133
    Likes Received:
    3,840
    I’d buy that for a dollar!
     
  4. Cheapskate

    Cheapskate Insane? or just stupid?

    Joined:
    13 May 2007
    Posts:
    12,449
    Likes Received:
    2,013
    Awesome! :D
    -Also, Where do you find a woman that cool?
     
    random2k4 likes this.
  5. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    Once I met her, I got 40 seconds to comply.
     
    Cheapskate likes this.
  6. censored_Prometheus_

    censored_Prometheus_ Minimodder

    Joined:
    26 Mar 2019
    Posts:
    198
    Likes Received:
    155
  7. Vault-Tec

    Vault-Tec Green Plastic Watering Can

    Joined:
    30 Aug 2015
    Posts:
    15,133
    Likes Received:
    3,840
    40 seconds is quite impressive for the first time. It beats 20 seconds any way :D
     
  8. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    Then it was already time to start.

    I have worked on multiple pieces at the same time, but I will try to
    organize the pictures as good as possible.

    Sterted with the feet that are mainly printed in PLA.

    [​IMG]

    To reduce a little bit of the weight, the front and side pieces of the foot will be roto cast
    later, but the template is printed in resin.

    [​IMG]

    And most of the parts were done.

    [​IMG]

    Most of the parts from the leg will be attached to an inner core that will hold all the weight of the mod.
    Inside the inner core, I already included all the holes for the mounting. Will have more detailed pictures later.

    [​IMG]

    [​IMG]

    Then I started sanding down the layer lines in my PLA prints. I also gave the resin parts a quick sand.
    Even if they are printed in resin, a slight sanding will really improve the later apperance.

    [​IMG]

    [​IMG]
     
  9. censored_Prometheus_

    censored_Prometheus_ Minimodder

    Joined:
    26 Mar 2019
    Posts:
    198
    Likes Received:
    155
  10. IanW

    IanW Grumpy Old Git

    Joined:
    2 Aug 2003
    Posts:
    9,324
    Likes Received:
    2,855
    random2k4 likes this.
  11. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    IanW likes this.
  12. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    And here is a picture of the two parts of the inner construction of the leg piece.
    They will be just pushed onto a 2x2 cm aluminum profile. This already holds up püretty good,
    but I also included two 6 mm threaded rods just for a better mounting.
    This way, I dont have to glue any parts, but could theoretically make changes or take
    everything apart if needed.

    [​IMG]

    [​IMG]

    Then I printed all the pieces for the outer shell of the leg.

    [​IMG]

    First sanded everything with 120 grid sanpaper and then glued all together.

    [​IMG]

    [​IMG]

    [​IMG]

    Smaller parts were printed on my Prusa MK3S and the larger ones on my Elegoo Neptune 3 Plus.
    The Neptune is a decent printer for the price, but the parts need more post processing than the Prusa ones.
    All the larger gaps were filled with Miliput, a two part epoxy putty.

    [​IMG]

    [​IMG]
     
  13. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    Unfortunately, I just realized now that my camera messed up
    the white balance in some images....

    After the main construction of the leg was done, I started with the detail parts.
    Working on this little part on the top and bottom side of the leg.

    [​IMG]

    As I need most of the details multiple times and also in more or less the same look.
    I decided to make mold and cast them in a cold-cast technique. This way, I will save some time
    in the Post processing, and all the metal parts will have the same look.

    First, I printed both parts in resin. This alone saves a lot of time in post processing as resin
    sands much better than ABS or PLA. Also much less sanding is needed.

    [​IMG]

    [​IMG]

    [​IMG]

    Then I built a simple card board mod box. I used Mold Star 30 (not 20T) as my silicone.
    A simple one part mold was more than enough for this simple piece.

    [​IMG]

    [​IMG]

    [​IMG]

    For a cold cast, you first need to dust the mold with some metal powder brfore pouring the resin in.
    I used Smooth-Cast 305 for most of the pieces.

    [​IMG]

    The cast parts looked a little dull right out of the mold. After polishing with some steel whool
    all was nice and shiny.

    [​IMG]

    [​IMG]

    A quick weathering with a brown and black wax followed.

    [​IMG]
     
  14. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    The next detail were also first resin printed and processed.

    [​IMG]

    [​IMG]

    [​IMG]

    Cause the back side of this pieces was important, I needed to make a two part mold.
    First I made a clay bed and layed the pieces on top.

    [​IMG]

    [​IMG]

    After the first half was done, I simply needed to spray a mold relsase on everything and
    made the seconf half.

    [​IMG]

    And the entire mold was done.

    [​IMG]

    The larger detail parts was just cast in normal resin. The smaller parts were cast again with a cold cast technique.

    [​IMG]

    [​IMG]
     
  15. Idioteque

    Idioteque Telephasic Mongoose

    Joined:
    21 Aug 2004
    Posts:
    1,616
    Likes Received:
    161
    [​IMG]

    Can't wait to see the end result!
     
    random2k4 likes this.
  16. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    Next, I worked on the mid sectinn of the leg.

    [​IMG]

    First all parts were again printed.

    [​IMG]

    [​IMG]

    I needed the cover on the side 4 times in total in metal optic. So I made a mold again
    and did a cold cast of all the pieces.

    [​IMG]

    [​IMG]

    [​IMG]

    While working on some parts, I realized that the back part of this section needed a very long time
    to get sanded down. So I made a little adjustment and printed that part also in Resin instead of PLA.
    That way I yould make a hollow cast of this part. UNfortunately, I missed taking some pictures,
    but I have some showing the process in a different section later.

    [​IMG]

    The next part, I also needed 4 times again, so I made a two part mold and cast everything.

    [​IMG]

    [​IMG]

    Again polished the cast pieces with some steel whool.

    [​IMG]
     
  17. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    Over time, I got quite some parts on my workbench.

    [​IMG]

    Luckily, I could print the arms as one piece on my printer.
    Minus the details ofc.

    [​IMG]

    [​IMG]

    For the rocket launcher of the right arm, I combined PLA and resin printed parts.

    [​IMG]

    [​IMG]

    The three cannons also have three magazins on the bottom part of the arms. To reduce weight and to fit the
    desig, they were also cold cast, but hollow.

    First, I prepared the master.

    [​IMG]

    [​IMG]

    [​IMG]

    I used Smooth Cast Onyx Fast, cause it only has a 3 minute pot live. Hat gave me enough time to poure it into the
    mold and rotate it to get the resin on every spot on the inside. After a partial cure, I repeated the procedure
    to get a little more thickness for the walls.

    [​IMG]

    [​IMG]
     
  18. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    To attach the arms to the main body, I printed some kind of ellbow.
    The holes are later used to incert a metal rod for stabilization.

    [​IMG]

    Cause the resin parts were too brittle, I decided to also make a mold and cast this section.

    [​IMG]

    [​IMG]

    [​IMG]

    Already predrilled the holes for all the screws and metal rods.

    [​IMG]

    Then, I could finally start building the "head" section. Just needed to cut it down
    to 4 pieces to fit on my printer. Makes filling a little easier.

    [​IMG]

    [​IMG]

    For stabilization, I glued two aluminum profiles to the inside.

    [​IMG]

    To further strenghten the section, I applied an epoxy coating to the inside.

    [​IMG]
     
  19. Cheapskate

    Cheapskate Insane? or just stupid?

    Joined:
    13 May 2007
    Posts:
    12,449
    Likes Received:
    2,013
    Super happy brackets
     
  20. random2k4

    random2k4 Multimodder

    Joined:
    11 Aug 2015
    Posts:
    386
    Likes Received:
    513
    They couldnt belive I actually use them for a project.
     

Share This Page