Scratch Build – Complete ⭐ Scratch Build: Rey's Speeder - Mod of the Year Nomination!

Discussion in 'Project Logs' started by Boddaker, 27 Feb 2017.

  1. Boddaker

    Boddaker Still hangin around

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    Mmmmmmmmm.... beer...
     
  2. Boddaker

    Boddaker Still hangin around

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    Another item I managed to check off the list over the weekend was the rear stabilizers. Pretty simple construction, just a couple pieces of 1/8" styrene, metal brackets and some hardware..

    The stabilizers are the slightly curved vanes that are mounted vertically on each side of the engine pods. A nice basic shape that didn't take very long to cut out of 1/8" styrene sheet and round the corners. I used my heat gun to add a slight bend to them.
    [​IMG]

    Next was to fab up a bracket to hold the stabilizers in place. I bent two pieces of 1/2" flat bar to fit around the 1" box tubing.
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    They just slide onto the tubing like so, and then I drilled some holes for a couple 1/4" threaded rods. The bottom one also serves to join the two brackets together in the middle.
    [​IMG]

    I cut a slot in each engine nozzle so they would fit over the brackets.
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    The top nozzle was drilled out on each side so the threaded rod goes completely through.
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    Taking advantage of the 3D printer once again, I whipped up some more custom brackets that bolt onto the back of the stabilizers..
    [​IMG]

    ..and they just slide onto the rods.
    [​IMG]

    [​IMG]

    And there you go.. I still need to cut down the fasteners so they are flush to match the threaded rod. I'm also looking into some different nuts to use.. maybe some acorn nuts or something that resembles rivet heads.

    [​IMG]
     
  3. Dr. Coin

    Dr. Coin Member

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    Nice work.

    What is special about your 3D printed parts that they glow?
     
  4. Boddaker

    Boddaker Still hangin around

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    Electro-lumininescent filament.. either that or its radio-active. :p
     
  5. stonedsurd

    stonedsurd Is a cackling Yuletide Belgian

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    you wouldn't download a nuke...
     
  6. Boddaker

    Boddaker Still hangin around

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    Lots of printing done over the weekend! Got the whole front nose assembled too. :)

    I started with the grill pieces.. These were printed a few weeks ago, but I wanted to wait until I had the entire front completed before posting pics. I was able to print the main grill as one piece..
    [​IMG]

    But for the trim, I had to cut it in half to fit it onto the bed. So I'll have to fill in the seam later.
    [​IMG]

    I also had to print the nose piece in two parts because it was so long. Had a bit of a mishap on the first attempt, as one of the legs tipped over mid-print due to it losing adhesion to the bed. But I was actually impressed with how it was able to correct itself and continue on.
    [​IMG]

    With a few modifications to the design and adding a raft, I was able to successfully print the bottom half of the nose.
    [​IMG]

    Then while printing the top half, the power went out and I had to restart the print, again. But I didnt want to start completely over this time, so I shortened the model to just print the rest of it. Here are all the pieces taped together.
    [​IMG]

    And with the center grill assembly..
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    [​IMG]

    I used Weld-On #4 to tack the pieces together, and will come back over the seams with filler to strengthen those areas. But for now, it's good enough to hold its shape and not have to use any tape.
    [​IMG]

    Next up is the bottom bracket, which I pretty much completed over the weekend as well. Oh, and then there's this too...
    [​IMG]
     
  7. Impeccable Logic

    Impeccable Logic Member

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    I also had to print the nose piece in two parts because it was so long. Had a bit of a mishap on the first attempt, as one of the legs tipped over mid-print due to it losing adhesion to the bed. But I was actually impressed with how it was able to correct itself and continue on.
    [​IMG]

    Granted my printer is not the same as yours, but mine would have ended up with the printhead/nozzle encased in plastic. :wallbash: So yes, nice recovery...

    Looking good!
     
  8. Boddaker

    Boddaker Still hangin around

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    Here is the bottom IO panel progress..

    I cut a piece out of an old Thermaltake panel to use for the bottom panel, utilizing the built-in mesh grill for ventilation. I've already cut out the IO opening for the motherboard.
    [​IMG]

    Got it in place, and marking the area for the graphics card.
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    Speaking of graphics cards, EVGA sent me this little gem!
    [​IMG]

    Now I can use it for mocking up instead of that crummy old Titan. ...KIDDING! :p
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    I also got the actual PCIe riser cable I'll be using in the build, from Li Heat.
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    Both card and cable installed and in place to finish up the bottom plate.
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    ..and done. The plate really serves to stiffen up the frame structure as well.
    [​IMG]

    One final shot of graphics card pr0n..
    [​IMG]
     
    Last edited: 5 Apr 2017
  9. kim

    kim Active Member

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    I love this concept, what you've done is just awesome...it's also amazing to see how much 3d printers enlarged the possibilities of modding...
     
  10. Boddaker

    Boddaker Still hangin around

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    Got some work to show, despite being in LA on Saturday for a modding workshop at Newegg, and then coming down with a cold shortly thereafter..

    Since the motherboard orientation is such that the IO panel is facing down, I needed to make a new panel at the back of the speeder for easier accessibility. And that's where these panel mount extension cables come in! I love these things. Here are the USB 3.0 cables.. one connects to the motherboard, while the other two plug into the mobo's IO.
    [​IMG]

    And here's the ethernet and displayport. I had to go with a shorty DP cable and a F/F adapter as that's the only thing they had for DP that was a panel mount.
    [​IMG]

    And last but not least, the power cable extension.. Home-made, using a standard power cable that was cut down, and a socket pilfered from an old psu.
    [​IMG]

    I cut out a piece of aluminum to fit just underneath the engine tubes at the rear bulkhead. After positioning the extensions, I proceeded to cut out the holes one by one. I put a piece of painter's tape over the actual plug and cut out the holes, then transferred the tape over to the new panel and marked it. It's not the most accurate method, but it gets me in the ball park, and once most of the material is removed, I just use the actual cable as reference from there on out to get it perfect.
    [​IMG]

    Continuing on, I got the USB ports done as well.. Another cool thing about panel mounts, is that you can use the other end to test fit your hole!
    [​IMG]

    And here's the finished panel-mount panel with panel-mounts mounted to the panel. :p
    [​IMG]

    Will show pics of the panel installed on the bulkhead next..
     
  11. Boddaker

    Boddaker Still hangin around

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    Here's the top panel progress..

    The total length of the top panel is about 14", and that is right at the max height of my printer. But I didn't want to push it, so I broke it up into two separate prints. This is the main part.
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    So far, so good..
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    ..and it finished! Total print time, 17hrs.
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    This part is 9 1/2" tall. The next part will be easier since it has a cutaway for the instrument panel and windshield.
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    A shot of the panel on the case..
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    Fits on there pretty well! I'll have a couple metal cross braces underneath that will match the curvature of the panel, and give it something to fasten to.
    [​IMG]

    And of course, I run out of filament with only 1/2" left to go! Fortunately, it was easy to pause the print and re-thread with a new spool.. except I don't have any more white, and all I have in PLA is pink (from my daughter's rose case) and purple. So, purple it is! :p

    [​IMG]
     
  12. Cleveland216

    Cleveland216 Carbon Fiber King

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    How 3D printing has changed case modding! Wish we had this 10-15 years ago when I was in college and had all the time in the world to build. You giving me ideas for my next case and to probably go the 3D printing route.
     
  13. Boddaker

    Boddaker Still hangin around

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    I am using my 3D printer quite extensively for this project, but only because its warranted. I don't think it will completely take over my future projects tho, because I see it as just another great tool in my garage that will help increase my productivity. :)
     
  14. Dr. Coin

    Dr. Coin Member

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    I'd say that statement has more weight for your vacuum table then it does for the 3D printer. Last couple projects of yours both have used printed parts.

    Great work. I'm amassed that that shell didn't fall or collapse on itself while you were printing.
     
  15. Boddaker

    Boddaker Still hangin around

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    Well, the Rose was my first ever print, and basically a warm-up to this project. :D I built my vacuum forming table specifically for the 737 fuselage back in 2006, and haven't used it since lol.

    But yeah, if it weren't for the raft at the bottom of the print, the shell would have undoubtedly fallen over. :worried:
     
  16. WanV

    WanV Member

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    what model your 3d printer machine?
     
  17. eucalyptus

    eucalyptus I am 19 and Swedish!

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    Definitely the PC of the Year! Holy cow Brian!


    Best thing I ever seen. The "I need this in my life" is strong with this one.
     
  18. MeMo

    MeMo It is what it is

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    Very Nice!!!! Happy Birthday!
     
  19. Boddaker

    Boddaker Still hangin around

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    It's a SeeMeCNC Rostock Max V2. :thumb:

    Haha thanks man!

    Thank you MeMo :)
     
  20. Boddaker

    Boddaker Still hangin around

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    So here's the IO panel installed on the back bulkhead, under the engines.
    [​IMG]

    A reverse shot of the other side..
    [​IMG]

    Moving up to the instrument panel, where the power button will be located, as well as the 2nd set of USB ports. I might throw a couple LEDs in there, if time allows.
    [​IMG]

    I have to cut down the bulkhead a bit, and make some other adjustments so all the pieces mate up better. Also will be adding a piece of styrene to fill in above the top instrument panel.
    [​IMG]

    Here's the progress on the exhaust ports, starting with the 3D model in Sketchup..
    [​IMG]

    ..printing.. I repositioned the top plate to print vertically next to all the tubes.. otherwise I'd need a lot of support material, which would be a waste.
    [​IMG]

    After a bit of cleanup, the top plate presses nicely over the tubes. Now I just need to cut a few holes in the bottom panel to mount it on the Speeder.
    [​IMG]
     

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