R2server [Archive] - Page 2 - TBCS Community Forums

crazybillybob

06-12-2006, 12:22 PM

Well here at the HillBilly Labs we've learned one thing this weekend....R2 Dome Suck!, They suck Time, Must be a special property of the Aluminum that it's made out of. Well my Plan to have this thing painted Saturday afternoon...Failed. The Dome was half etched when I started Friday night, It took another 6 hours to finish the etching, 6 Hours to finish adding all the holes, 5 hrs to mask and prep for paint, about 3.5 hours to prime and paint.
But It's painted!! And I didn't get that video up for you all :( Sorry R2 Hasn't moved again since the first day (to busy with the dome!), To add to the mess I realized Sunday morning that the center foot has never been bondoed :shock: So I spent a few hours working on that (while paint was drying outside). But You guys want PICs.....Here you go!

Here I'm etching the dome. The Dremel (Craftsman type) Is no longer with us....It coughed up smoke and blue sparks several hours after this pic was taken....Still under Warranty...So Back it goes....Current count R2 2 Dremels 0
http://www.thebestcasescenario.com/cbb/R2/Me_Dome_etch_Big.JPG

To make the Various Sized round holes in the dome I used a single bladed hole cutter (Widow Maker) to etch a perfect circle about 1/4 through the aluminum. Then I made the center hole much larger (so the Jig saw blade would fit) then I cut lines from the center to the outer ring, that left me with "Hanging Pie" pieces. I used some pliers to bend the pie wedges in and out till the broke off. The hole cutter was set to be just abit smaller then I needed Then I used files and a sanding drum to bring the hole to the correct Size. (not pictured) The Squareish and rectangle holes were cut out with the Jig saw (Dremel died trying to cut the first pie wedge) then filed to size.
http://www.thebestcasescenario.com/cbb/R2/Dome_Hole_cut_Big.JPG

Here's the Dome Etched and Cut Ready for Masking!
http://www.thebestcasescenario.com/cbb/R2/Dome_Etched_Cut_Big.JPG

Masking was a two setp Process, The fist being to mask the edges of all the panels to be painted blue.
http://www.thebestcasescenario.com/cbb/R2/Dome_mask1_Big.JPG

The next Setp was to cover the large areas that will stay silver after painting.
http://www.thebestcasescenario.com/cbb/R2/Dome_Mask2_Big.JPG

Once Masked I wiped the exposed parts down with denatured alcohol (again). Then 3 coats of primer was laid down (forgot to snap pic). Then 3 Coats of Metallic Purple was applied.
http://www.thebestcasescenario.com/cbb/R2/Dome_Paint_Prup_Big.JPG

Next 2 coats of blue candy was applied.
Followed by 4 coats of Clear.
http://www.thebestcasescenario.com/cbb/R2/Dome_Painr_Blue_Big.JPG

A hairdryer was used to help speed up the drying time between each coat...(The Temps dropped to 55f Shortly after sundown Sunday night)

While the Primer and others were drying ( and to get me away from the dome) I laid and sanded a coat of bondo on the center foot, The picture is of the second coat of bondo (filling in some air bubbles and low spots).
http://www.thebestcasescenario.com/cbb/R2/Cent_Foot_2nd_Bondo_Big.JPG

Tonight I'll remove the paint mask from the Dome and Start mounting the Holoeyes and L brackets for the attachment of dome to Disk, as well as finish up the sanding of the Center foot (hopefully I'll get some Primer on it too!). I'm not going to Promise anything on the Video but I'll get one up ASAP!

Now Back to Work!

CrazyBillyBob

tybrenis

06-12-2006, 03:05 PM

Great job, CBB. How are things looking for MML? I won't be able to make it this year, but I look forward to seeing lots of pics from it! Maybe you could take some pics for us of you and the other competitors.

crazybillybob

06-12-2006, 03:22 PM

Oh, I'm sure that Some MML pics will surface again this year.. :) I'll do my best to snap a few when I'm not gameing or answering Q's and what not!

CrazyBillybob

Rankenphile

06-12-2006, 05:11 PM

great as always, CBB. It's really coming along nicely. That's a pain that it took so long to get the dome done, though. That is one thing I have learned many times over in my life - estimated time to completion is about half what it will actually take, no matter how conservative the plan.

crenn

06-12-2006, 06:43 PM

Nice work.... but you haven't said anything about the circuit I posted up for you......

crazybillybob

06-13-2006, 10:43 AM

Cernn,

It's still a posibility, but I'm not working on the Electrical system just yet. I'm in High gear to get R2 Presentable by well Tomorrow, so I'm not ignoreing you, and I thank you for your input, I just have not had time to ready sit down and see if it will fit in and how to make it fit in....But that is coming. I'm going to take a month or two off after MML (got some Home owner things to fix....Like a roof, a deck and installing a new patio...Deal I made with my wife so that I could pour the last few weeks of my life into R2 and ignore everything else!) But once I get back the Elec system in high on my list, cause I want the pc to run while I'm not plugged in. Sorry man, but that's where I'm at. and again THank you, I do Appreciate the input!

CrazyBillybob, Tired, blury eyed and behind!

crazybillybob

06-13-2006, 10:44 AM

It was another late night @ HillBilly Labs. Progress was made and Pitfalls Appeared :( But The Mood was light and the hour late.

After some work with a razor knife (to free the tape from the paint, by scoring a line at the edge of the tape, you pro's have got to tell me what I did wrong!) The dome's paint job appears. And He looks good in Hypo Blue !!

http://www.thebestcasescenario.com/cbb/R2/Dome_dry_big.JPG

And After much thought and discussion (thanks Dave, Tolk, and My Wife) The feet were painted (Ok Primered) White... I know that before they get a final cot of paint that there is a bit more body work to do, so the white primer does two things it blends the body and feet together and points out some of the spots that need to be fixed..... It's both Form and function, I love it when a plan come together (name that 80's Tv Show, and for bonus point the character that made it famous!)
The Center foot (leg details in the background)
http://www.thebestcasescenario.com/cbb/R2/Cent_Foot_White_big.JPG

The Out Side Feet
http://www.thebestcasescenario.com/cbb/R2/Outer_Feet_white_big.JPG

The Hand made L Brackets to hold the Dome to the Plastic Ring were fabed (just some alum L channel cut to 1/2" lengths with a 1/4" hole drilled in the "Bottom" side. I laid out 8 points on the inside of the dome about 1.5" up from the lip. The Brackets were then mount in place with JB-Kwik (the tape is just to keep them from moving till the JB setts!), also the Screws for the Rear Logic display were JBed into place.
http://www.thebestcasescenario.com/cbb/R2/Dome_PlateMounts_Big.JPG

Now on to the computer type front, The motherboard Tray had it's brass stand offs installed. Hopefully the mobo gets mounted and the OS will be loaded today.
http://www.thebestcasescenario.com/cbb/R2/Mobo_Tray_nuts_Big.JPG

Your Reading this going , he said pitfalls, I don't see any pit falls???
We're getting to that point now. I tried to get one of each of the major detail pieces painted in there proper color last night, with grave results. I'm not sure what happened but on the booster cover the blue clouded up with in minutes of being applied (didn't use any clear....just more to sand off). The utility Arm had an even worse reaction the Paint just bubbled up and off of the arm... The only thing that I can think of is that I was close to the end of the can of blue candy and was trying to finish with what I had (the auto store is closed at 11pm here, and it's the only color that I don't have 2-3 cans of :( ) So these pieces will need to be stripped down, but I'm not sure that they'll get done before MML....(Not on the Priority list any more!)

So It was a mixed night, but I got allot done (What I don’t get home from work till 7Pm, and 2am is bed time...Still have to work :) )

Tonight will be mounting night, Every thing gets installed in R2. Dome Details, Battery supports, PC, HDD....you name it it's getting stuff in place. Also My wonderful wife is going to head up the R2 Crate project for me tonight (thanks babe!!!)

CrazyBillyBob

Trying to "Work" work done .....and failing, my mind keeps drifting to R2.

crazybillybob

06-13-2006, 10:48 AM

Missed the Pics of the Bad Paint.

Clouded Booster Cover
http://www.thebestcasescenario.com/cbb/R2/Clouded_blue_big.JPG
Blustered Utility Arm
http://www.thebestcasescenario.com/cbb/R2/Blistered_Blue_big.JPG

CrazyBillyBob

crenn

06-13-2006, 11:13 AM

Crenn,

It's still a posibility, but I'm not working on the Electrical system just yet. I'm in High gear to get R2 Presentable by well Tomorrow, so I'm not ignoreing you, and I thank you for your input, I just have not had time to ready sit down and see if it will fit in and how to make it fit in....But that is coming. I'm going to take a month or two off after MML (got some Home owner things to fix....Like a roof, a deck and installing a new patio...Deal I made with my wife so that I could pour the last few weeks of my life into R2 and ignore everything else!) But once I get back the Elec system in high on my list, cause I want the pc to run while I'm not plugged in. Sorry man, but that's where I'm at. and again THank you, I do Appreciate the input!

CrazyBillybob, Tired, blury eyed and behind!

I can see you're tired instantly by the fact that you spelt my name wrong! ;)

I just hadn't heard anything from you, so I was beginning to think you either didn't like it or you hadn't noticed it. If you want, I can give you the extra notes you'll need, it also explains how the circuit works and what problems may occur with it, it will also include what type of diodes you need.

And you're welcome, if you could actually see my 'modding' book, you'll find quite a few pages of modding notes and electronic circuit designs. So this isn't a hassle, also the fact that the circuit I designed, most of it was on my mid-year physics exam! I just added a little (charging circuit, and changing a couple of things)

Thallion

06-15-2006, 04:15 AM

I love it when a plan come together (name that 80's Tv Show, and for bonus point the character that made it famous!)

That would be the A-Team, and I believe the character's name was Hannibal, IE the leader of the team.

Looking good!!!!!

crenn

06-15-2006, 06:47 AM

I believe the character that made it famous was Mr. T.

EDIT: I better make it clearer. Hannibal, made the quote "I love it when a plan comes together" famous, but Mr. T made the show famous with his quote "I pity the fool"

Mach

06-18-2006, 09:38 PM

:D

http://www.thewsvg.com/images/Image/gallery/g7_full_IMG_0589---.jpg

http://www.thewsvg.com/images/Image/gallery/g7_full_IMG_0588---.jpg

http://www.thewsvg.com/images/Image/gallery/g7_full_IMG_0588---.jpg

http://www.thewsvg.com/images/Image/gallery/g7_full_IMG_0589---.jpg

crazybillybob

06-19-2006, 04:35 PM

Here's the video that I promised :)
The First one is a short demo of R2 Running.
http://www.fccmonline.com/LanImages/R2/films/R2Dancing.avi
For fun R2SRV was entered into the MR. WSVG contest, here he is doing a dance.
http://www.fccmonline.com/LanImages/R2/films/MRWSVG_R2.avi

More pics from MML will show up shortly.

CrazyBillyBob

Rankenphile

06-19-2006, 05:59 PM

that is so cool, man. I'm proud of ya. Nice work.

Aero

06-20-2006, 04:17 PM

ha, sweet. Its really coming along. Glad it came togather for MML.

lol, whats that little not. "Do not _____" I'm going to guess touch, but still looks amazing.

crazybillybob

06-20-2006, 07:28 PM

ha, sweet. Its really coming along. Glad it came togather for MML.

lol, whats that little not. "Do not _____" I'm going to guess touch, but still looks amazing.

One of the guys that went to MML with us stuck the do not disturb sign from my hotel room on R2 (people touching him and all when he was sitting on server row) with the hopes that housekeeping would wake me up friday morning..... They didn't :) Left the hotel before they came round.

CrazyBillyBob

crenn

06-21-2006, 03:12 AM

Very nice, all you need now is it to be autominous!

crazybillybob

06-21-2006, 09:46 AM

Very nice, all you need now is it to be autominous!
That is something I'm looking At for the future....I need to get him completed first, then start upgradeing him to Autominous.... maybe a couple years :)

CrazyBillyBob

crenn

06-21-2006, 10:08 AM

Well, if you need a hand in something, I'll always be happy to help, I'm a bit of a robotics 'geek'.

crazybillybob

06-21-2006, 11:39 AM

Great...I'll add you to the list (got a few others that volunteered to help if I need it). But It will be a bit till I get back to work on R2.... I'm going to take a few months off, I promised my wife that I'd fix a few things around the house before I dive back into R2 (It was our little deal so that I could blow every thing off for the last four weeks....I mean everything She's great took care of it all!!!!)

I've got a few smaller R2 things to work on (which means there will be some posts here.....just not as many as normal) The outer feet need pined, and I'd like to see the Projector in place real soon. But I'm going step away for a bit (helps keep the burn out away!), But never fear I'll still be here hanging out in the forums!!!

CrazyBillyBob

Aero

06-21-2006, 01:13 PM

whoa. wait.....projector.

Ok, I know it only makes sense but that would be amazingly awesome.

crazybillybob

06-21-2006, 01:18 PM

Yeah, Go back into my work log, I go into some details on how to make your own.... I think the end cost was less then $50us..... not counting the ac to dc convesion I'm doing (using a boat load of UB LEDS for a light source instead of a bulb). It's built I just need to get the light source installed then the whole projector mounted into R2.

CrazyBillyBob

Thallion

06-22-2006, 03:11 AM

You know If I ever built an R2, one thing it would have to be able to do is follow me around. Now I have no idea how this could be accomplished, but something like a radio emitter on your person and some kind of receiver that can tell direction and distance in R2 itself. and then a program that tries to maintain x distance away from you at all times. Then you have it setup so it has the follow program active or the remote control active, so if you want to do something you can whip out the remote, other wise he rolls along following you.

I notice in the moving videos the outside leg feet are not aligned with the ground, but aligned with the leg supports, yet I could swear the feet should be parrallel to the ground.

Looks awesome great to see it moving!

crazybillybob

06-22-2006, 10:29 AM

I notice in the moving videos the outside leg feet are not aligned with the ground, but aligned with the leg supports, yet I could swear the feet should be parrallel to the ground.

Looks awesome great to see it moving!

Your Absilutly Right, The Foot shells kept moving on me (even though they are Torqued down as tight as I can get them), It's due to the weight of R2 and the speed/Torque that is being transfered as he rounds the corners. That is also why I Want to pin the feet as soon as I can.

As for the Auto Track, It's a feature that I've thought about but will only be able to make happen when/ if I make R2 autonimous..... Still Wrastling with this, he weighs in at around 150Lbs, and is very fast....he could hurt some one very easily and I plan on taking him to childrens events when completed...That could be bad news together. But it's still a thought.

CrazyBillyBob

crenn

06-22-2006, 10:20 PM

The speed controller should make it so R2 can move slowly.... and I think I might have an idea for getting R2 following you around, it will be a couple of things. If you want it mentioned now, either post here or PM me about it.

DaveW

07-09-2006, 08:05 PM

I had missed this worklog for a while somehow, it's great to see so much progress in so little time. Well done CBB, i can't wait to see you finish this completely. :)

What's the battery life like on the little critter?

-Dave

crazybillybob

08-28-2006, 10:52 AM

This Log is not dead!!!
R2's coming back from Summer Vacation Shortly :)

Dave,

Battery Life is Crazy....On one Set (2 X 12V 4.5AH) R2 Ran At MML for 4-6Hrs....That's the DRIVE SYTEM :) and he's got 2 sets a Primary and a backup. I'm very happy about the Run Time. I have to keep both sets of Batts in R2 So that He Doesn't do wheelies so much....(Still does plenty of wheelies thou.....In fact I've had him Flip over on his back....An other R2 Builder saved him from hitting the floor ). I'm still looking for a big 12V Batt (12-18AH) for the PC side. I've got Lots of Things to do to R2 and now that my Summer Time "Out Side" home Improvements are wrapping up I'll get back to them.

Ready to MOD!!!
CrazyBillyBob

GT40_GearHead

08-29-2006, 03:37 AM

it's a live bwhaahahaahha

Crow_T_Autobot

08-29-2006, 02:17 PM

CrazyBillyBob,

I wanted to use my first post on this board to say thanks for all the great detail you're sharing with the rest of us on this project. I've learned so much reading through all the work logs on this site, and seeing what has already been done has inspired me to try my own.

R2 is one of my all time favorite robots, and it's amazing to see one being built step by step like this. And he's a functioning PC to boot. That's just awesome! 8)

crazybillybob

08-29-2006, 10:02 PM

Crow,
Thanks for the Praise :) I'm glad you like the worklog. I'm looking forward to showing everyone some of the new.....Budget building that will be going on soon. Lets say I've learned about a low cost source for ridge PVC and a simple low cost way to thermo form it. I think it should be fun for all.

CrazyBillybob

crenn

08-31-2006, 09:57 AM

Heh, the day I finally decided to come back to TBCS, it's 2 days after you post! Good battery life, can't wait for the larger battery. I may be able to help you on the wheelie problem, but that's going to involve calculations and weighing the unit. But hey, I'm still here if you need help!

crazybillybob

09-13-2006, 01:58 PM

Well now that summer is drawing to an end I'm back working on R2-SRV, but before we get into that some pics from the 2nd annual Midwest builders meet held in Chicago on Aug. 5 this year. Target Practice drove up from Columbus, Ohio to attend with me. The Turn out was good, It was held at the Comfort Inn so we had a few of the kids staying the drop in to see why all the R2's were running around, (Just something about one of these little guys driving through the parking lot that draws a crowd).

http://www.thebestcasescenario.com/cbb/R2/MWBM06_big.JPG

There were some new Droids there, The purple one is quick! The beat up two legged Droid is made out of Cintra (PVC foam core boards), the dome is Resin (it weighs more then the body does!!), it's static display model but pretty :)
http://www.thebestcasescenario.com/cbb/R2/Purp_plast_big.JPG

Everyone's favorite Little Mini R4 was back too.
http://www.thebestcasescenario.com/cbb/R2/Mini_big.JPG

And Of course we had Food, Good Droid Food :)
http://www.thebestcasescenario.com/cbb/R2/DBGoodFood_big.JPG

The Builders Meet Really got me fired up to finish R2 (plus I've got some Ideas for a new mod but one at a time....for now ) But a vacation, and boat load of work (work work ,and wife work) has keep me busy since then. But I finial got to work this weekend on R2.

I'm trying to make a set of stiff inserts for the front doors (on the right and left of R2's chest). I have the outer layer there in styrene, but the doors keep wanting to flatten out, and the body is round so it doesn't work so well. The doors are to be moveable (open close) so that I can put things in there.....not telling what yet don't want anyone hopes to get dashed :) This spring I get a set of battery boxes for R2 from one of the other builders (he makes then in his basement) and there made out of PVC pipe, heated, reshaped, with extra PVC parts glued on. He also showed a group of us how to reform PVC, it was easy. So I thought after my fiber glassing mistakes that I'd try the PVC path for these doors.

First thing to do was get some pipe......Off to Home Despot!
http://www.thebestcasescenario.com/cbb/R2/PipeFullleng_big.JPG
An 8 foot section of 3.5" thin wall PVC pipe....Perfect

After a meeting with the Chop saw....A more manageable 20" piece of pipe.
http://www.thebestcasescenario.com/cbb/R2/Pipe_cut_big.JPG

Next a trip to the table saw, to split one side of the pipe length wise (pic didn't turn out of this)

Then I heated the PVC with my heat gun...Spread it out (Make sure to wear gloves that plastic gets HOT!!!) Reheat and smash between two pieces of 3/4" plywood. You get some thing like this...
http://www.thebestcasescenario.com/cbb/R2/Pipe_flat_big.JPG

I know your thinking....That's not going to help make the doors curved....your right, but it makes it easier to remold it when it's flat.

So I broke out my handy dandy R2 Shaped form thingy
http://www.thebestcasescenario.com/cbb/R2/oldform_big.JPG

Heated the PVC and formed it over the plywood section.
Well the our come sucked, It's too deeply bent in the middle, too shallow on the edges and there's a big dimple in the center.... :(
http://www.thebestcasescenario.com/cbb/R2/Deformed_big.JPG

Well I got looking at my form (cause every thing I pull off it is screwed up the same way.) there are high spots where the support members are, low spot where there not and the edges flex way to much....it's junk!

So I decide that I'll make a solid buck this time. After a bit of tracing (the out side edge of R2 where the doors will be) I came up with this Profile template.
http://www.thebestcasescenario.com/cbb/R2/profiletemplate_big.JPG
So I know how high and wide the buck needs to be. If I glue up some 2x4" scrap it'll fit, after a quick dive in the scrap box I get the pieces I need. Then I realize that I don't own any bar clamps...and this thing is going to be 18" long and 12" wide....what to do??? Redneck Tech..I pulled out my ball of bailer twine (yes this really came off of hay/straw bales) and some scrap wood. The Twine goes around the pieces to be glued then into a hole at each end of the scrap wood. This way when you twist the scrap wood you tighten the string.....Being that this is a buck and not a finished work, I just dry wall screwed the scraps to the buck to keep them from loosening.
http://www.thebestcasescenario.com/cbb/R2/redneckclamp_big.JPG

( No one's Questioning my Handle now are they :) )

The Gorilla glue dried over night, I'll scrap off the extra with a sharp chisel.
http://www.thebestcasescenario.com/cbb/R2/BlankGlued_big.JPG

Then Run the ends through the table saw (so we know that there square) and we've got a 17" blank.
http://www.thebestcasescenario.com/cbb/R2/Blanktrimed_big.JPG
Now two more trips through the table saw to get as much extra wood off as we can before the profile is roughed in (the profile was drawn on the end of the blank to set the cuts)
http://www.thebestcasescenario.com/cbb/R2/Blankbeveled_big.JPG

With all the Wood removed that can be with the saw, the blank is clamped to the bench and Roughed in by hand (yeap, a jackplane , Chisel and rubber mallet).
http://www.thebestcasescenario.com/cbb/R2/Buckforming_big.JPG

Once it was roughed in (very close to perfect), the belt sander smoothed things up, I check the profile intermittently with the profile template, marked the hig spots and sanded them down, checked marked , sanded...repeat till perfect.
http://www.thebestcasescenario.com/cbb/R2/buckfinished_big.JPG

At this Point I heard the Announcer on the radio say "Good Wednesday morning, it's 12:07 here at " and realized I need ed to be going to work in a few hours.....sleep would be smart. So I'll see how this buck works and let you all know !

It’s Great to be back !!!!

CrazyBillyBob

Crow_T_Autobot

09-13-2006, 03:24 PM

Glad to see you were able to move forward on this again.
The creativity in making the forms and jigs is great. By the time you're done with this, you'll have all the tooling to make more really easily if you wanted to.

Drac998

09-13-2006, 07:00 PM

Man that just too cool.

crazybillybob

09-28-2006, 12:31 PM

After much delay and deliberation, I've started on the Dome Electronics...Yeap some of the R2 Bling will be going in.

I'm starting first with the front logics. These were Designed by the founder of the R2 builders club, with this run being made by Ben and Jason (ok, I helped in the Prototype stage and finding the PCB fab shop).
The Displays, randomly flash and fade 40 3mm Ultra Bright LEDs (mix of Blue and white) It also has the ability to scroll a message across like a marquee, when triggered. The Message is programmed by a serial connection. (think a little adapter and hyperterm), and trigger by dropping the trigger line to Gnd.

This is what I started with....Looks like fun :)
http://www.thebestcasescenario.com/cbb/R2/LogicParts_big.jpg

After some work and a bit of time (about 45min to an hour each) I ended up with these things.
http://www.thebestcasescenario.com/cbb/R2/LogicASSMB_big.jpg
The LEDs a packed very tightly so soldering them is painful!

But the Results they are worth it!
http://www.thebestcasescenario.com/cbb/R2/Logicon_big.jpg
You'll not that it looks like the lights are turned off in the room in this picture. They are not, in fact it's as brightly lite as is was in the previous two pics. The LEDs are so Bright the camera darkened everything around them.

The next step is to be able to trigger that scrolling message remotely. To do that I need a remote switch..... Well I've got less channels on my 7channel remote then I've got thing to switch (ok or planed things :) )
So I'm going to start making a multiplexer....sort of.
I'm going to make a plate that will allow a servo ti sit in the middle and toggle diffrent switches on and off based on how far the servo wheel spins.

I'm starting with a piece of that flattened PVC I have left over from the door panels gone bad.
http://www.thebestcasescenario.com/cbb/R2/PVCSMFLAT_big.jpg
Then I'll cut out a square the size of the top of the servo, and mark and drill 4 pilot hole for the screws to hold the servo to the PVC. Then mount the Servo.
http://www.thebestcasescenario.com/cbb/R2/RCSWITCH_BIG.jpg
I also had to use a bit of scrap PVC to raise the roller switch to the correct height. As I add more devices I'll be adding more roller switches. In the above pic the switch is in the off position.
http://www.thebestcasescenario.com/cbb/R2/RCSWITCHON_big.jpg
In this pic you can see that the roller has fallen into the notch that is cut into the servo's wheel, this is the on position. The great thing about the roller switches is that they have both normally open (when no pressure is on the switch there's no connection) and normally closed (when no pressure is on the switch there is a connection). What this feature allows me to do is depress the switch when I want it off and turn it on when I release the switch.

Now I need to work on mounting the Logics....That will be next time on this old Droid!

CrazyBillybob

once mounted I'll get some video of the scrolling message.

DaveW

09-28-2006, 01:03 PM

I love this worklog. It's one of the best here at TBCS.

-Dave

crazybillybob

10-11-2006, 11:13 AM

Part of today's update will be off on a tangent.
Over the weekend I setup R2 to be a Mechwarrior 4 Mercs Online Server, with the MekTek Mech Packs ( Downlaodable here (http://www.mektek.net/mekpak/download.html?B3=I+AGREE)). He's up 24/7 come and join in (Redneck Games). So I've been playing a bit of Mechwarrior lately! I've got these cool joysticks for it (Saitek X45's) and found out they work in BF2, and BF2142 (they didn't work in BF1942 that's why I stopped using them) Well Sitting back in my Desk chair my lap was getting crowded and I was getting my butt kick because I had to fish the track ball up off the floor, or one of the joysticks, or I'd hit some keys with the joys it was just bad.... So I built a couple of little shelves for my Chair and mounted my Joysticks there (think Rocket Man!!!)

http://www.thebestcasescenario.com/cbb/R2/PilotChair_big.JPG

Now everything is Right at hand and mounted solidly (makes flying in Bf so much easier :) )

Close up of Joy
http://www.thebestcasescenario.com/cbb/R2/JoyR_big.JPG

The Saitek Joysticks have mounting slots built into the base, so I just bolted them to the little shelves, a bit of self adhesive Velcro under the TrackBall so it stays where I want it! Very happy with this Rig!

Ok, now to the small R2 update.

To allow the Dome to spin there is a bearing mounted under the dome like so:
http://www.thebestcasescenario.com/cbb/R2/Dome_BearingInstall_big.JPG

So far I've had the bearing only attached to the body frame by 2 screws into this temp Spacer across the middle of the top frame ring.
http://www.thebestcasescenario.com/cbb/R2/Temp_Bearingspacer_big.JPG

It worked ok, but over time the weight of the dome bouncing as R2 drives around has started to deform the mounting area on the bearing, as well as letting the Dome bounce back and forth about 1/2" not good! To fix this I'm making a new spacing ring that is .9" thick and 18" in Dia. With a 6" hole in the center. I'll be making it in a similar fashion as the rings for the frame were made...but I've learned a bit so I'm going to apply that new knowledge to make thins go smoother :)

http://www.thebestcasescenario.com/cbb/R2/BearingSpacer_layout_big.JPG
Here we've got the 1/4" birch Plywood and the 3/4" birch plywood, you can see that I have the lines laid out for the 18" circle and the 6" hole. You will also note that there is a circle in between the two, this is where the screws that hold the bearing will go, it will be very helpful in lining up my screw placing template that I made up in CAD.
That's where we're at now... I'll get the rings cut and trued up this week and mounted. I know your thinking is that ALL? nope I've been working on a bunch of stuff for in the dome, but it's not real exciting or photo able yet. I'm working on how to mount the LED matrixes, and the PSI lights...Trebly boring stuff but it must be done... Their also calling for snow here starting tomorrow...So My thoughts of painting this weekend are shot! maybe I'll make the LDP (large data port....It's the blue curved rectangle on the front of R2 just below his dome) not sure yet. Oh, I almost forgot R2SRV is Folding (I'm trying to find the cure Are you?). Till next Time!!

CrazyBillyBob

DaveW

10-11-2006, 12:17 PM

Good to see you're still alive CBB ;)

Nice chair mod. Definately stick some speakers in there now for immersive surround sound.

And get a buttkicker.
(http://www.thebuttkicker.com/ButtKicker%20Gamer_home.html)
-Dave

crazybillybob

10-11-2006, 12:24 PM

Dave the buttshaker is neat but If I were to go that way....I'd get a bas shaker on e-bay for $20-$40, then strip the amp out of one of these spare sets of pc speakers I have here. Some thing just $80-60 cheaper :)

CrazyBillyBob

DaveW

10-11-2006, 06:41 PM

Go for it man, you know you want to!

-Dave

crazybillybob

10-26-2006, 01:23 PM

It's been awhile since I've updated everyone on my progress. I have been working more on R2 then will be in this update (gotta get some more pics), but work has been getting in my way of getting a post up (this Fiscal year can't end fast enough!).

In the last installment you saw the bearing spacer plate laid out on square stock. This time you'll see how I get that square perfectly round.

First I cut out a rough circle with the scroll saw (for the 1/4" piece) and the jig saw (for the 3/4" piece). The layout circle was a guide and I tried to leave between 1/8" and 1/4" of space between the cut and the layout line. The out come looks like this.
http://www.thebestcasescenario.com/cbb/R2/ThicRoughspacer_big.JPG
http://www.thebestcasescenario.com/cbb/R2/ThinRoughspacer_big.JPG

I created a jig for my router table that allows you to make a perfect circle. It's a piece of 1/4" plywood bolted to the router table with a screw in it, real high tech stuff :) By adjusting the distance between the edge of the router bit and the screw I can adjust the diameter of the circle. To mount the wood to the jig I drilled a 1/8" hole in the center of the board. then use the jig screw to hole the board to the jig. Here's the thin board mounted to the router table.
http://www.thebestcasescenario.com/cbb/R2/CircJigRouter_big.JPG

Just turn the router on and spin the board around, and out come this.
http://www.thebestcasescenario.com/cbb/R2/Thikrout_big.JPG

Now I just have to mount the bearing to it and center the whole thing on R2's body....more to come on this.

While I was working on the spacer I figured it was time to take care of those detail pieces that had the blistered paint on them.
http://www.thebestcasescenario.com/cbb/R2/Details_Depainted_big.JPG

After the paint was removed the booster cover got another coat of primer
http://www.thebestcasescenario.com/cbb/R2/Booscovprime2_big.JPG
This is just the first of many!

It's kind of good that the paint on the utility arm bubbled because I didn't like how rough parts of it looked once the paint dried (the area's that didn't bubble) so I started reglazing it, hoping that it will help make the finish smoother this time.
http://www.thebestcasescenario.com/cbb/R2/UtArmputty_big.JPG

Being that the highs up here are only 50F it's going to take a few days for this stuff to dry so I'll get back to it later. I don't want any cracks or such in them.

It's a lite update for being quite so long but I've been working on some more body details and I'm going to have to adjust some of the drive components so there's more to come real soon (seeing that I've gotta have my little buddy up and running in just over a week for a LAN party)
:)

Your humble hillbilly astromech tech,
CrazyBillyBob

Doober

11-14-2006, 04:41 PM

Billybob...

HI! I've been watching this, casemodgod, etc. forums for a while, I'm contemplating building a case (yours looks sweet by the way :)). Anyway, I saw you were from Lansing, and was wondering if you went to a LAN party at the Royal Scot's 19th Hole back in September. There was an R2 case there, with the LED electronics you speak of, but it doesn't seem like the timeline of what you have posted lines up with the LAN party, as the R2 I saw there was together, though it looked like it was still a work in progress (it was remote controlled as well). This wouldn't have happened to be yours, would it?

MDCS

11-14-2006, 08:38 PM

Now that's a mod!
Just watched your dancing video ... so cooooooool! :D

crazybillybob

11-21-2006, 06:34 PM

Doober,
That was me @ Royal Scot's 19th Hole. The Lan I'm talking about is not that one, I run a lan in Ohio (about 5 hours from Lansing). WaldoLan was fun, I'm tring to get some guys to come up for the new years party.
This work log is more or less current. It's crazy the amount of things that I have changed in this mod just because I didn't like them or found a better way to do it after the fact That no one else will notice or even see.
The Big update is that the MOBO in R2 took a dirtnap after the last Promised L.A.N., got home tried to boot nothing no post, no beep just the fan spinning. But I talked (e-mail) with mini-box and it's on it's way back to be replaced...nice guys.

Let me know if you gots Q's (I work in Ann Arbor...so I'll be in and out)

CrazyBillyBob

Billybob...

HI! I've been watching this, casemodgod, etc. forums for a while, I'm contemplating building a case (yours looks sweet by the way :)). Anyway, I saw you were from Lansing, and was wondering if you went to a LAN party at the Royal Scot's 19th Hole back in September. There was an R2 case there, with the LED electronics you speak of, but it doesn't seem like the timeline of what you have posted lines up with the LAN party, as the R2 I saw there was together, though it looked like it was still a work in progress (it was remote controlled as well). This wouldn't have happened to be yours, would it?

ajmilton

11-22-2006, 11:58 AM

d'oh, saw CBB post and thought there was worklog update to be had

such a tease :P

SgtM

11-22-2006, 04:36 PM

CBB, what LAN do you run in Ohio? Where is it located? I live in Niles on the NE side of the state.

crazybillybob

11-23-2006, 03:10 AM

sgtm,
I run the Promised L.A.N. We were in Malvern for 3 years, the last one we had was begining of Nov and it was in Carrollton (also NE Ohio....South west of you abit down 11 like 1hr or so) We've switched from every month to a few times per year (the fact that I have to travel 5+hours to get there and take a day off work promted that desision) we list on Lan addict and Lan party...I'll make sure to post something here before the next party.

CrazyBillyBob

Also I hang with the Lanohio Crew...great lan party every month in Canton. In fact their haveing a Lan on Saturday check out www.lanohio.com

Aero

12-08-2006, 06:07 PM

Hey BB, did you ever get that copper traceing down for the 360 degree head spin? I'm kinda thinking of something similar for a project I'm designing right now. Only with alot more juice, I was wondering if there was a limit to the amount of electrcity that could be transfored if I went with that method (or one similar).

Also, hows R2 work with power? Like when its moving around is the computer on, are they seperate systems? Hows that whole deal working out?

crazybillybob

12-11-2006, 12:01 AM

Aero,

I've started looking a diffrent direction for R2's swivel power interface I'm looking into comercial slip rings there not cheap but they can handle more power and alot more signals (like 24 total lines). The Circuit board one that I was looking at makeing would have handled maybe a couple of amps. How much power it could deliver is based on the thickness of the copper on the board, the width of the trace and the surface area of the transfer (the more surface are where the brush and trace meet the lower the resistance = more current).

As for the powering R2's CPU while driving around....I've not implemented it yet. But I'm much closer now, I've just need to order the 12V 12AH battery and build a circuit to charge the battery while alowing the CPU to run from it at the same time. That was a little harder to figure out then one would think, I had to talk with one of the guys I work with to come up with the charging circuit, I just need to buid it now :)

Sorry that's all the help I've got.
CrazyBillyBob

crazybillybob

12-11-2006, 12:03 AM

So By now your all thinking that I've give up on R2...NOPE Just a little busy.
The part I've been working on has been kicking my butt. The shape has been difficult to covert from 2d Drawing (think a picture with dimensions) into a flat-pack (a drawing that’s used when your going to form everything out of a sheet of flat metal) It's got an angled cut on a curve that took me abit to work out. In this ref pic here there's a cylinder in the way but you get the Idea.
http://www.thebestcasescenario.com/cbb/R2/AnkleDetail_ref_big.JPG
With everything laid out
http://www.thebestcasescenario.com/cbb/R2/AnkleDetail_laidout_big.JPG
The Hard part is done Now I just cut each peice out
http://www.thebestcasescenario.com/cbb/R2/AnkleDetail_cutout_big.JPG
Then Clamp it up for Brazing, I'm Brazing instead of welding because tese parts are not structural and it's easier to do on this thin sheet metal (22ga).
http://www.thebestcasescenario.com/cbb/R2/AnkleDetail_clamped_big.JPG

With It all brazed up and a light bit of sanding (to get all the slag off), The First one is done! One more to go
http://www.thebestcasescenario.com/cbb/R2/AnkleDetail_brazed_big.JPG
I only built one at first to make sure my math and drawings were right :) now that this one worked out I'll go ahead and finish the second one (already have it cut out).

The mother board should be back soon, Once that's back I think I'm going to redesign the mother board tray, as I think that it flexed to much and that's what casued the failure.... So if anyone has any new Ideas please let me know!

Well back to the shop!

CrazyBillybob

samurai_crip

01-09-2007, 01:47 PM

woooaa This looks amazing :O

R2 FTW!! :banana:

crazybillybob

01-23-2007, 12:54 PM

In this Installment of this old Droid we're showing you how discount LED Christmas lights can be used to Pretty up your Droid. :)

A long while ago you all saw me Drill an absurd number of 3mm holes ( 108 ) in some 1/8" aluminum.
http://www.thebestcasescenario.com/cbb/R2/ALumBez_big.JPG

Well I dug it back out for use till a new custom Display can be built (that Scrolls Messages like the front).
Here's the items I have to work with
http://www.thebestcasescenario.com/cbb/R2/RLogic_Supl_big.JPG
The LED Christmas lights were on Clearance ($3ea) at Walgreens, but I had to have a Friend ship them in from Florida, Seems the Walgreens here in the North didn’t carry them at all this year. Each set has 20 LEDs strung together, so I'll be using 6 sets (the extra will be bundled up and hidden. They will be driven by a "Pic Flasher" from Carl's electronics (http://www.electronickits.com/kit/complete/ligh/ck1007.htm). The LED Strings run on 4 AA's (6V) the Flasher runs on 9V so I'll just switch out the Resisters that come with the kit for some 390 ohm ones, which will keep the LED's from burning up when run on 9V.

After several hours of random insertion and hot glue you get to this (not quite done but getting there) There's like 3hours of watching movies and burning my fingers in there pwned Not to everyone, Hot glue is hot, and sticky it stays moltten for awhile, and hurts the whole time :) so don't get it on you.
http://www.thebestcasescenario.com/cbb/R2/Rlogic_INPROC_big.JPG

After Testing all the LED strings I tidy up a bit, some black tape, some final connections to the Pic Flasher we're ready to go.
http://www.thebestcasescenario.com/cbb/R2/RLogic_Neater_big.JPG
Nope, Some idiot wired all the LED strands backwards to the Pic Flasher... :( It's so Hard to get good help these days!)
By the time I figured that out It was too late in the night to pull all the wires out of the Flasher and fix it.
So Next Time on this Old Droid (tonight) I'll get it rewired, and film the lights running (video forth coming).

Thanks for Tuning in to This Old Droid.
Up next DYI Hyperdrives

CrazyBillyBob

This is my first step into the Dome Electronics, I'm hoping that it will kick me in the butt and I'll get the rest pumped out soon ( with the holidays, and my wife not in school for the last 2 months. my motivation has been lacking, hopefully this will change now).

SgtM

01-23-2007, 05:06 PM

Lookin good CBB. Keep up the good work man!

DaveW

01-23-2007, 06:29 PM

You sonovabitch. I can't believe you had the balls to come back. What, you keep me waiting this long, then when i give up, you spring one on me? Well tough man, this ship has sailed.

...I forgive you. :) And i can't believe how cool that looks. You Pwned that glue dude, not the other way around.

-Dave

crazybillybob

01-24-2007, 11:50 AM

Just to Prove that I'm not Scared of you Dave!! :bunny: :banana: :santa:

CrazyBillyBob

This Space For Rent

<

crazybillybob

01-24-2007, 11:50 AM

I've gotten the wiring sorted out on the Rear Logic display.
http://www.thebestcasescenario.com/cbb/R2/RLogic_on_big.JPG

The Blinking pattern is ok, Not sure what I was hoping for, but it will do!

Here's a Quick link to a Video of the display in action. (http://www.fccmonline.com/LanImages/R2/films/RLogic_mov_big.MOV) (it's 36Mb so modems beware! and you'll need a MOV player like QuickTime to view it).

Now that the display is complete I'm moving on to the next system....
Sound :) I'm starting out with this nice Chinese made I-Fraud I-shuffle Mp3 player.
http://www.thebestcasescenario.com/cbb/R2/Sound_nomod_big.JPG

I'm toying with the Idea of making it radio controlled...How by hacking a cheap Zip-Zap Knock off (that I got last year @ MML for being on a loosing team in Ubisoft's GRAW Tourney....Clancy Section did have it's benefits)
I've gotta do some testing on both first. If you've got any Ideas please share them with me (and the rest of the class :) )

Next time the Dissection of the I-shuffle (and maybe the car)

CrazyBillyBob

DaveW

01-24-2007, 01:11 PM

If you want to make it radio controlled, go to a local hobby shop and see what they have in terms of remote control kits. You might be able to get a nice long range remote and a powerful receiver for cheap. You might also get this stuff on Ebay.

The logic panel looks cool! Surprised you managed to do it without any glue leading out the holes.

-Dave

jdbnsn

01-24-2007, 01:29 PM

That display is too cool dude, great craftsmanship as always!

crazybillybob

01-24-2007, 01:39 PM

Dave,
I'm considering that method as well. I've seen some kits on ebay that are controlled by a keychain remote, All I need really is a 4 button jobby. From my first set of tests I'll need to attach relays tin place of the buttons on the Mp3 player. So If relays are going to cost me much I'll go with the kit (they come with relays), but i'll post some pics of the car so others see what I found out... might help someone out :)

CrazyBillyBob

crazybillybob

03-01-2007, 05:38 PM

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!!!
http://www.thebestcasescenario.com/cbb/R2/Reardoor_hingealinement_big.JPG

With the hinges in you need something to keep the door shut... So I installed a magnetic latch.
http://www.thebestcasescenario.com/cbb/R2/Reardoor_magLatch_big.JPG
Here's a nice view with the latch installed.
http://www.thebestcasescenario.com/cbb/R2/Reardoor_Latched_big.JPG

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.
http://www.thebestcasescenario.com/cbb/R2/Front_skinless_big.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/ALUM_SHEET_MB_BIG.JPG
After a little run in with the Masking tape roll, and marker the Box is laid out ready to cut.
http://www.thebestcasescenario.com/cbb/R2/MBBOX_Layout_BIG.JPG
This stuff is tough to cut!! took 1.5 hours to cut this out on the scroll saw.
http://www.thebestcasescenario.com/cbb/R2/MBBOX_FLAT_BIG.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/MBBOX_halfFold_BIG.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/MBBOX_EISO_BIG.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/MBBOX_TOPV_BIG.JPG
http://www.thebestcasescenario.com/cbb/R2/MBBOX_ISO_BIG.JPG
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

Zephik

03-02-2007, 11:01 AM

Will this be a moving or non moving build CBB? What I mean is, will it move around like the real R2D2?

3 weeks with a robot and no wife, that almost sounds like a good thing. lol

DaveW

03-02-2007, 12:25 PM

3 weeks with a robot and no wife, that almost sounds like a good thing. lol

It's official, we've hit a new low for geekiness.

-Dave

crazybillybob

03-02-2007, 02:02 PM

Snow,
R2 will move around like the Real R2D2...In fact he (R2SRV) made a showing at last years MillionManLAn....

I've posted these before but Here you go again...R2SRV in action

The First one is a short demo of R2 Running.
http://www.fccmonline.com/LanImages/R2/films/R2Dancing.avi
For fun R2SRV was entered into the MR. WSVG contest, here he is doing a dance.
http://www.fccmonline.com/LanImages/R2/films/MRWSVG_R2.avi

CrazyBillyBob

Will this be a moving or non moving build CBB? What I mean is, will it move around like the real R2D2?

3 weeks with a robot and no wife, that almost sounds like a good thing. lol

crazybillybob

03-15-2007, 10:48 AM

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).
http://www.thebestcasescenario.com/cbb/R2/CenAnkLayout_big.JPG

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.
http://www.thebestcasescenario.com/cbb/R2/CenAnkPartWeld_big.JPG

With all the welds in place and cleaned up, it's time for a test fit.
http://www.thebestcasescenario.com/cbb/R2/CenAnkDryfit_big.JPG
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!!)
http://www.thebestcasescenario.com/cbb/R2/Fangdlayout_big.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/FanGDcutout_big.JPG
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...
http://www.thebestcasescenario.com/cbb/R2/FanGdMisssized_big.JPG
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

intergalacticman

03-16-2007, 01:46 PM

Cause there’s like 5 people out there that aren't SW Geeks that knows what an R4 is everyone else will ask "What is it?" But R2 everyone knows. And there's many different Types Of R2's Yours Is an R2D2 mine is an R2-SRV. So they are different. :D

Crazybillybob

i know what an R4 is:D

NOT a star wars geek 8)

intergalacticman

03-16-2007, 01:49 PM

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.

CrazyBillyBob

you build replicas of r2D2 and still have a wife
was that an accident or something??:D

JKJKJKJKJKJK sorry i had to say that
building a working R2D2 server really takes some skill

crazybillybob

03-16-2007, 03:43 PM

you build replicas of r2D2 and still have a wife
was that an accident or something??:D

I started R2 after I got Married.... had some free time on my hands and needed another challange!

And Building a R2 replica doesn't take skills it builds them.... Trust me I didn't know allot of things before I started this mod I've learned allot along the way.... The point of the trip is sometime the journey.

CrazyBillyBob

intergalacticman

03-20-2007, 04:38 PM

The point of the trip is sometime the journey.

CrazyBillyBob

wow quite the philosopher also i see:up:

crazybillybob

04-04-2007, 09:52 AM

wow quite the philosopher also i see:up:
Nope,
Just a GEEK :banana: Philosopher's have more free time :)

CrazyBillybob

crazybillybob

04-04-2007, 01:48 PM

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)
http://www.thebestcasescenario.com/cbb/R2/outerankle_mounted_big.JPG

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.
http://www.thebestcasescenario.com/cbb/R2/Centerankle_mounted_big.JPG

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.
http://www.thebestcasescenario.com/cbb/R2/Slipring_recev_big.JPG
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.
http://www.thebestcasescenario.com/cbb/R2/slipringDB25_big.JPG
Getting all these wires hooked up and tested is an on going process so expect 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.
http://www.thebestcasescenario.com/cbb/R2/Fangaurd_fixed_Big.JPG
While I was cutting stuff I took a few minutes to cut a lid out for the Motherboard protection system....Nothing fancy...
http://www.thebestcasescenario.com/cbb/R2/PCPS_Lid_big.JPG
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).
http://www.thebestcasescenario.com/cbb/R2/Speakermount_big.JPG
Looks nice, Lets test fit it with the speaker.
http://www.thebestcasescenario.com/cbb/R2/Speakermount_testfit_big.JPG
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 @ 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

crazybillybob

04-18-2007, 09:43 PM

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.
http://www.thebestcasescenario.com/cbb/R2/Halfmoon_big.jpg
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)
http://www.thebestcasescenario.com/cbb/R2/psipcb_BIG.jpg
With the board made and soldered up, I needed some thing to house it.
http://www.thebestcasescenario.com/cbb/R2/PSIPasrt_big.jpg
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.
http://www.thebestcasescenario.com/cbb/R2/psiasmb_BIG.jpg
When mounted in the dome you get an effect like this Video of Lights running in the dome! (http://www.thebestcasescenario.com/cbb/R2/films/PSIInOP.MOV) (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! (http://www.thebestcasescenario.com/cbb/R2/films/FLDInOP.MOV)

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).
http://www.thebestcasescenario.com/cbb/R2/MPS_PWRSWT_big.jpg
Also the Fan hole has been drilled.
http://www.thebestcasescenario.com/cbb/R2/Fanhole_big.jpg
I know I know you want to see that Sweet R2 Fan guard mounted over that hole..... OK, stop twisting my arm! :)
http://www.thebestcasescenario.com/cbb/R2/FanGuardmntd_big.jpg

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

DaveW

04-20-2007, 02:30 PM

Damnit CBB! You hurry up and finish that little critter, ya hear? :p

-Dave

crazybillybob

04-20-2007, 05:06 PM

Dave,
I'm trying, If work would stop getting in my way :)
IT WILL BE DONE BEFORE JUNE 21, 2007 (even if I don't sleep for the last week!!)

By the way, which Pic uP do you recomed learning on? I think I'm going to take the plung (picked up a good book on programing them recently on work trip).
Just want to make it easy on my self.

CrazyBillyBob

DaveW

04-20-2007, 05:43 PM

I learned PIC Assembly on a standard 8 pin PIC, doing some basic things like learning how to use the variable input/output to drive 8 LED's from 4 lines and so forth. A small and simple PIC will make life easier.

All you have to remember is that it uses Harvard Architecture (http://en.wikipedia.org/wiki/Harvard_architecture) instead of the John von Neumann model (http://en.wikipedia.org/wiki/Von_Neumann_architecture). Once you figure that out, it suddenly becomes much easier!

Good luck dude! It's been nearly a year and a half since i did any programming lower than C, so i feel rusty now. :(

-Dave

crazybillybob

04-20-2007, 08:15 PM

don't worry about screwing up the architecture.....It's been so long since I wrote any assembly code for an Intel based system....I forget it....the basics are still there mov regA to Workreg and regc to workreg place result in regD
That I remember syntax and commands ...aAaaaa nope. The whole moveing that program from one mem page to the other, and remembering the stack isn't accessable from the second page.....???:? That's where it gets tricky.

I just ordered a 28 pin....I think 20 I/o picXXF57XX it's referanced in this book, I'm going to try and run it on a 16Mhz crytal Hope it's not too fast for me :)

I'm sure as I go I'll be asking for help. Think I'll us one in my next mod :) (still don't know what that will be at this point)

CrazyBillyBob

crazybillybob

05-15-2007, 10:46 AM

Spurred along by G00se's I7W7 (http://www.gruntville.com/phpBB2/viewtopic.php?t=19870&sid=eae34a7dc5f009ef525a77011f4f77df) 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.
http://www.thebestcasescenario.com/cbb/R2/halfmoonwelded_big.jpg

The half-moon details will be mounted on the sides of the feet Like this (minus the hand ;) )
http://www.thebestcasescenario.com/cbb/R2/MoonfootPreview_big.jpg
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.
http://www.thebestcasescenario.com/cbb/R2/Armsprep_big.jpg
Here you can see one arm coated in putty the other has been primed and sanded, a few spots have been filled in again....Rinse and repeat!

http://www.thebestcasescenario.com/cbb/R2/BoostersPrep_big.jpg
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.
http://www.thebestcasescenario.com/cbb/R2/slipringinstall_big.jpg

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 :)

http://www.thebestcasescenario.com/cbb/R2/domeMotor_big.jpg

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

crazybillybob

05-15-2007, 03:05 PM

Thanks, Minty. Hopefully I'll have something more for you to watch soon!

CrazyBillyBob

crazybillybob

08-20-2007, 09:46 AM

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.
http://www.thebestcasescenario.com/cbb/R2/paint_mask_big.JPG
http://www.thebestcasescenario.com/cbb/R2/paint_mask2_big.JPG

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)
http://www.thebestcasescenario.com/cbb/R2/body_painted_big.JPG

I also found some Great stuff for cases, It's Cheap, looks good and holds paint well... What is this miracle stuff?
http://www.thebestcasescenario.com/cbb/R2/screenroll_big.JPG
That's right Aluminum window screen.

http://www.thebestcasescenario.com/cbb/R2/screen_painted_big.JPG
This one layer painted and cut to size.

http://www.thebestcasescenario.com/cbb/R2/Screen_placed_big.JPG
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 modders mesh before.

Then there's the night before MML (we took off @ 3am Thursday...I didn't sleep at all that night)
http://www.thebestcasescenario.com/cbb/R2/R2work02.jpg
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 Wiring finished..and some repairs from shipping damage)
http://www.thebestcasescenario.com/cbb/R2/R2work03.jpg
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!!
http://www.thebestcasescenario.com/cbb/R2/R2kiss.jpg
R2's first kiss.
http://www.thebestcasescenario.com/cbb/R2/jedi03.jpg
Some Jedi younglings and their Masters.
http://www.thebestcasescenario.com/cbb/R2/gruntville.jpg
Then there's always the Grunts :)
http://www.thebestcasescenario.com/cbb/R2/droidrace01.jpg
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
http://www.thebestcasescenario.com/cbb/R2/hubblnk_big.JPG
Added a little Lathe (8x12" model)
http://www.thebestcasescenario.com/cbb/R2/lilllathe_big.JPG
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
http://www.thebestcasescenario.com/cbb/R2/hubcut_big.JPG

With a little work (drilling and taping a setscrew hole) and mounting the wheel you get this ...
http://www.thebestcasescenario.com/cbb/R2/dome_rotr_big.JPG

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!! (Edit:....Made It home!!!)

CrazyBillyBob