PDA

View Full Version : R2-D2 by Frenkie



Frenkie
02-19-2008, 05:18 PM
http://www.thebestcasescenario.com/jdbnsn/worklogbanners/r2d2.png

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

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY01.JPG

Lets get an old PC case from the attic.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY02.JPG

Quickly disassembled.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY03.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY04.JPG

Hmm, a bit too big. Gotta make that a bit smaller.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY05.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY06.JPG

For all you starting casemodders; always wear eye protection. Trust me.
Also used some ear protection, as the bin was working as a drum.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY07.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY08.JPG

Thats off, now the sharp edges.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY09.JPG

Lets try the tray. I see I have to fold the edges.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY10.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY11.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY12.JPG

For use as "vents" i dug up these ancient ( 1984 ) grills from speakerboxes.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY16.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY17.JPG

Used the dremel to cut the hole for the vent.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY18.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY19.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY20.JPG

Later on, I see the vents don't stick out at all. I made a small container to hold the fans.
I made it from Vikureen (http://www.vinkkunststoffen.nl/Default.aspx?ID=5507)

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY21.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY22.JPG

My sponsor SpacePromotion (http://www.spacepromotion.nl/) provided me with two 60 mm fans with white LEDs.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY23.JPG

Hmm... that doesnt fit because of the extra wires for those LEDs.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY24.JPG

Bit of creative cutting.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY25.JPG

LEGS.

A stack of MDF wood and some wood-glue.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS01.JPG

Something like this.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS02.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS03.JPG

First cuts.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS04.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS05.JPG

Using the workmate and clamps the legs are taking form.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS06.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS07.JPG

With some sanding they look now like this.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS08.JPG

Frenkie
02-19-2008, 05:39 PM
Starting chapter three; the DOME

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME01.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME02.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME03.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME04.JPG

And these two for the FRONT-DISPLAYS.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME05.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME06.JPG

Back to chapter one, the BODY

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY26.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY27.JPG

-sorry, one photo missing here-

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY28.JPG

The skirt sides.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY29.JPG

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

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

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS09.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS10.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS11.JPG

More MDF and some aluminium for the support frame.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS12.JPG

Something like this.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS13.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS14.JPG

Fitting in the case,

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS15.JPG

Bolted to the bottom.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY49.JPG

Frenkie
02-20-2008, 04:43 PM
Made a Rader-eye holder from some MDF.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME07.JPG

Round it off and fitted the eye glass.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME08.JPG

For the two Front-displays I bought two Velleman circuits, orginally with red
LEDs, but I wont be using those. Instead I bought in Hong Kong a few hundred blue and white LEDs for 0.99 Euro per 100 )

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME09.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME11.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME12.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY30.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY31.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY32.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY33.JPG

The guys at Space Promotion gave me this ZALMAN fancontroller (http://www.zalman.co.kr/eng/product/view.asp?idx=274&code=017).

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY34.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY35.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY36.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS20.JPG

Does'nt look too bad.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS21.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS22.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS23.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS24.JPG

Glue it with construction glue.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS25.JPG

And there it is.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS26.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME13.JPG

Pre-drilled the LED holes.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME14.JPG

Bended it with a heatgun until it matched the curves.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME15.JPG

Then drilled the final 5 mm for the LEDs.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME16.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME17.JPG

All LEDs in and glued.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME18.JPG

Quite a mess eh ?

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME19.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME20.JPG

Frenkie
02-20-2008, 05:02 PM
Made some strips of Vikureen for the rectangle parts that come into the round outerlayer.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY47.JPG

Neatly follow the lines and break it of. ( the plastic, not the scalple )

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY48.JPG

Also from Space Promotion (http://www.spacepromotion.nl/) i got these Zalman harddisk coolers (http://www.zalman.co.kr/eng/product/view.asp?idx=74).

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY39.JPG

At first I wanted to mount them on the bottom.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY40.JPG

Then decided to mount them as high as possible.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY42.JPG

Dremel dremel dremel..... a hole !

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY43.JPG

The supports are the same as for theZalman fancontroller (http://www.zalman.co.kr/eng/product/view.asp?idx=274&code=017). ( type QeD ;) )

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY41.JPG

Preparing the table legs for mounting.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS27.JPG

Screw them on.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS28.JPG

An old cilinder that used to contain wire.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS29.JPG

Cut in half and measured it.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS30.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS40.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS41.JPG

Spray painted the dome and radar-eye holder.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME21.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME22.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME23.JPG

made a hole and glued it on.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME24.JPG

From the front.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME25.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME26.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME27.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME28.JPG

Started to glue the LEDs into it.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME29.JPG

When it is on, it looks like this.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME30.JPG

With Gelly Roll pen's I coloured the circuit a bit. With regular light you dont see anything...

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME31.JPG

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

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME32.JPG

Frenkie
02-23-2008, 05:21 AM
Through Ebay I got me this second-hand slot-in DVD player, removed the outer casing
and gave it a spot inside the case.
By removing the casing, the exit comes as close to the outer edge as possible.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY44.JPG

Inserted a DVD disc, now I can determine where it must go through.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY51.JPG

Made the first cut, from the inside out, with my new cordless Stylus dremel.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY52.JPG

And here you see the cut from the outside.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY53.JPG

Cut it over the whole length, and -theoretically- the disc should go through....

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY54.JPG

Yes, I said theoretically, because allthough it looks very slick, the disc damaged enormously
when coming through. It is simply too tight.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY55.JPG

Too bad, but nothing else to do but make the slot wider and use a few strips of
plastic to round of the edges.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY56.JPG

When the case is spraypainted white, this looks allright.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY57.JPG

In the end I decided to add that third leg after all, to gain more stability.
Starting with some MDF wood.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS31.JPG

Taking the measuerments, added a hinge pin.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS32.JPG

The female part.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS33.JPG

And the male part of the hinge.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS34.JPG

Glueing, sawing, filing and sanding, you know the drill.....

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS35.JPG

And here it is, a third leg with a hinged foot.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS36.JPG

Beside its two big brothers.

http://clan-rag.gameparty.net/bitchie/case/12/Legs/R2_LEGS37.JPG

Some sawing the edges. ( actionshot :) )

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS38.JPG

Made it in the proper dimensions and stuck on with construction-glue.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS39.JPG

When its all done, this will be white and I will add two blue mini-CCLs underneath.

-------------
A remark from the guys at Gathering Of Tweakers:
The two stright up legs gives a strange look.

Well, he is right, it doesnt look -right-. So, I will have to modify the two "finished" legs as well.
The standard angle for this robot is 18 degrees, so I will modify the legs at the ankles to give me that look.

http://www.thebestcasescenario.com/frenkie/r2d2/2-3legs001.jpg

-----------

Overall shot of the dome.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME33.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME34.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME35.JPG

The radar-eye glued to the dome.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME36.JPG

And in the hole beneath it, I glued in a old reflector I had laying about.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME37.JPG

Allthough not 100 % satisfied, I glued the Velleman circuits in it too.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME38.JPG

This is how it looks from the front. Maybe some tinkering with smoke-plexi to cover those LEDs a bit.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME39.JPG

Frenkie
02-23-2008, 05:51 AM
BTW, the lenght of the third leg is determined to get the centre of gravity right between the three legs.

On the front of the droid there are two so called utility arms.
In the real R2, these are retractable arms with gadgets that R2 uses a lot.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY58a.JPG

I choose only to use the looks of them, so I cut out silhouets (?) of those two arms out of Vikureen polystyreen.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY58b.JPG

But offcourse, the plastic is nice and straight and the case nice and round......

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY59.JPG

So on with the heatgun ... ( Vikureen is a thermoplast )

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY60.JPG

Now they both have the same curve and I can glue them on proper.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY61.JPG

Giving the fancontroller a spot.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY62.JPG

Making the hole.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY63.JPG

And there it is.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY64.JPG

Here the fancontroller will look out.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY65.JPG

Made wires to the DVD switch and a little polystyreen container for the DVD player.
The excisting case was to ridgid and too large to fit back on.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY66.JPG

Making a piece to size and two cuts in it.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY67.JPG

Bend it over, but not too far.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY68.JPG

And it should look something like this.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY69.JPG

In the front of R2 there is this "coinslot". Calculated it from the blueprints and milled it out.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY70.JPG

And more of the front panels in Vikureen.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY71.JPG

Just like the two before, I used the heatgun to give the most of the panels the right curve.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY72.JPG

Only the long straight ones wouldnt bend like I wanted it too. If all failes I will use
pinstriping to get it on there.

Frenkie
02-23-2008, 04:00 PM
A friend donated me an old 40 Gb harddrive which stil runs.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY73.JPG

Just like in my plexiglass lansuitcase mod...........

http://clan-rag.gameparty.net/bitchie/case/7/Case.PlexiSuitcase.60.jpg

.........I removed that ugly sticker from the top with the heatgun.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY74.JPG

Then mounted the Zalman HD cooler again.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY75.JPG

Looks allright to me.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY76.JPG

BTW, the PC I am using this time is an antique :) An old redundant office PC, I got for free, A P4-2800 with 768 Mb memory and a 64MB GFMX400 racemonster.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY77.JPG

From the side.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY78.JPG

I had to bend several edges of the backplane. Mounted it together with rivets.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY79.JPG

The PC is now rock solid attached to the case, plus I have created a new reference point to carry on from here.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY80.JPG

Made some polystyreen 'frames' to mask a few ugly edges. One around the connector plate, one for an extra casefan and one around the Zalman powersupply. ( I had to tear that power supply pretty bad to fit it inside.)

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY81.JPG

Mounted the support frame tight to the case.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY82.JPG

On the inside you see a small USB extension bracket what I needed to attach the webcam.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY83.JPG

The support frame is the next reference point and there I started attaching the HD cooler.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY84.JPG

And the opposite side of the support frame attached.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY85.JPG

This should look familiar to you.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY86.JPG

Yes indeed, a standard power/reset and LED layout of that basic grey office PC. almost forgot that I needed to turn the R2 on and off sometimes. :)

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY87.JPG

I rerouted the HD activity LED to the dome. Because I have a few battery operated lights in there, there had to be an few on/off switches too. These three are saved from the garbage dump.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY89.JPG

You cant see them, there on the bottom. First a pre-drill.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY88.JPG

Then enlarged it to the proper size.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY90.JPG

Als from the garbage dump, a few plexi plates for underneath the feet.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY104.JPG

Small hole for the LED.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY105.JPG

Something like this, only the in blue. ( I used the red coz it was nearest to me :) )

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY106.JPG

To give the legs the neccesary 18 degrees, I manufactered two new aluminium brackets.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY107.JPG

This is how they will come in the feet.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY108.JPG

I had some time left, to make a new overall photo for your entertainment.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2-NOV007.JPG

Frenkie
02-23-2008, 05:19 PM
The two ankle joint brackets slots milled in the wood. Frontside with the half circle and the rear side where that bracket fits in perfectly.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY109.JPG

Started to make small polystyreen plated, to give a bit more depth to the outside.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY110.JPG

Bad news; my new kick-ass Zalman fancontroller doesnt fit.
The motherboard is a tad too large and in the way of the box.
I will have to think of something new to make it fit again.

Put the parts together....

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY111.JPG

.... and it looks like this is gonna work out perfect. Exactly 18 degrees ánd another 4 inches longer. Now I have to plaster and paint it.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY112.JPG

=====================================

The local newspaper picked up my cases and made an frontpage article out of it.
Maybe this will give the casemod-scene a new boost and brings a bit more understanding to the people who have NO idea what we do what we do. ( yes those people exist ! )

http://clan-rag.gameparty.net/bitchie/case/LD02-500.jpg

Frenkie Janse uit Brunssum 'pimpt' al jaren computerkasten. Een aparte hobby
die hem al heel wat prijzen opleverde. Vorig jaar werd hij zelfs
kampioen casemodding in de Benelux.

http://clan-rag.gameparty.net/bitchie/case/LD04-500.jpg

http://www.limburger.nl/article/20071205/REGIONIEUWS05/160341368/1056

Een computerkast met raampjes en lampjes erin is al niet bijzonder meer. En ook
een verlichte ventilator kom je op gamefeestjes vaak tegen. „Als je op een
LAN-party twee dezelfde kasten hebt is het eigenlijk al niet meer leuk. Ik wil
een aparte computer." Dat is voor Frenkie Janse de drijfveer om te beginnen met
case-modding, ofwel het 'pimpen' van computerkasten.

Lees het hele interview met Frenkie in de krant van donderdag.

===================

You know that problem I had with the fancontroller? Thanks to some friends the solution was swift and simple, just how I like it.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY117.JPG

I opened the controller and indeed, about 90 % of the box is empty space.
The part that was in my way, was coincidentally also a part that was easily removed.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY118.JPG

Some support brackets for the controller.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY119.JPG

Here it goes, the rear circuit I can hang wherever I want.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY120.JPG

Mock-up with two polystyreen strips.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY121.JPG

Inside the case.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY122.JPG

To connect a lot of the electricical stuff that runs from the body to the dome, I used this big connector.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY113b.JPG

The connector in the dome.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY114.JPG

The HD-activity LED in the reflector inside the dome.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY115.JPG

And from the front. Its a highpower LED, so in conjunction with the reflector this should give a huge amount of light.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY116.JPG

Frenkie
02-25-2008, 05:31 PM
this thing is really amazing. you say that it is a low-budget mod, but you can not see that at all. I'll have to +rep you for that...

No no no please dont please dont ! I'll do anything for you !
( just kidding, THANX! )

The skirt and the underside painted first layer. The blue CCLs come underneath here.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY126.JPG

The third foot sanded, plastered, sanded again, and first layer white on it.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY127.JPG

The three legs together after the first layer.
Maybe some blue pinstriping after the second layer.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY128.JPG

Painted the utility-arms.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS42.JPG

The three blue LEDs underneath the feet.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY129.JPG

Used hotglue to set it at the right height.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY130.JPG

Three plexi plates on it and ready.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY131.JPG


***
ontopic, my casemod(s) were on local television here in the south of Holland. Here is a weblink for those who are intrested http://www.tvl.nl/site/load.php?page=28&item=4085&modID=48&temID=14&mode=module

***

Little experiment with the LEDs underneath the feet. I taped some reflecting tape underneath
them to try and get a bit more light out.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS43.JPG

First shot, LED is off.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS44.JPG

Second shot, LED on, No tape underneath.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS45.JPG

Third shot, LED on, and reflective tape underneath.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS46.JPG

Well, be honest, I did not see a major difference.... :S
Ah well, that still didnt hold me to stick it underneath the skirt as well.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS47.JPG

And here come the two blue CCLs.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS48.JPG

How to get the wire from the LED to the body.
Made a dremel cut with a disc with a width of 1 mm.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS49.JPG

First wire falls right in.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS50.JPG

And second wire fills up the cut.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS51.JPG

Did the entire lenght.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS52.JPG

And here it goes around the corner.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS53.JPG

Cut with wire in it, used rapid-glue to hold it down for a few seconds.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS54.JPG

Then added the blue pinstripe.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS55.JPG

More leg details. Cut out some disc out of Vikureen polystyrene.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS56.JPG

Cut it right in half.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS57.JPG

Enough for three legs on both sides.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS58.JPG

A pen.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS59.JPG

The cap of a pen.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS60.JPG

A cap of a pen with some earthwiremesh ( is that english? ).

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS61.JPG

Sanded the cap to get a more elegant connection.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS62.JPG

Foiled the mesh and put on a rubber ring.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS63.JPG

And this is how it looks now.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS64.JPG

Frenkie
02-25-2008, 06:03 PM
Added polystyrene plates on the three legs, and I think it looks quite allright.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS65.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS66.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS67.JPG

Close-up of one of the legs.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS68.JPG

Connected them just for the photo, this one with the lights on....

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS69.JPG

....and here with the lights off.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS70.JPG

Oh yeah, quickly gave the satelite dish a spot of paint.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME44.JPG

Experimented with some matte plexi. but I did not like it.

http://www.thebestcasescenario.com/frenkie/r2d2/Dome/R2_DOME45.JPG

A lot of plates in different sizes.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY133.JPG

Cut vertically into the plates.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY134.JPG

Close-up of the cuts.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY135.JPG

Left side of the case, with plates in random order.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY136.JPG

And the right side.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY137.JPG

Both CCLs mounted underneath and worked the wires to through the bottom.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY138.JPG

Found some more inspiration for those pesky switches. I'm gonna make them stealthed.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY139.JPG

Made two sets.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY140.JPG

Drawn and milled.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY141.JPG

Made a hole and one side of the hinge.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY142.JPG

Tricky bit: drilling a 1.4 mm drill in the topside of a 2 mm polystyrene plate.
As you can see, a lot of times it just didnt go well :)

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY143.JPG

In the end I was left with 4 minute little blocks of about 2 x 2 mm.
And a hole in the top plate of 1.4 mm.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY144.JPG

Stuck together and glued.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY145.JPG

And here is the result, two little hinged "boxes' that contain the on-off switch and
the reset switch.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY146.JPG

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY147.JPG

Here about they will be place. Made two holes for the original switches.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY148.JPG

And glued the switches behind the holes.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY149.JPG

Frenkie
02-27-2008, 04:25 PM
Weekend! So free during the day, day light and it was dry outside,
this means I could get started with the paint.

First layer.
http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY152.JPG
http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY153.JPG

And turning the case a third for the next piece.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY154.JPG
http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY155.JPG

Taking it easy, one piece at the time. After the third layer I will add some pinstripes.

Thought off another idea ! An R2 without the bleeps and the bleeps isnt really any good right?
After some searching ( mainly size and budget-like ), I came upon this high-tech
Ipod look-a-like speakerset for a measily €3,49. :P

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS71.JPG

Dismantled it. I tested the "set", and it runs just fine on the PC's 5 Volt.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS72.JPG

Now the best part; Where to put the speakers? Inside the Dome? Inside the Body ?
NO! In the LEGS! If you compare my legs with the "real" thing, you see I am missing
the outside hinge-axel. At first it didnt bother me one bit, but since the speakers are made
from reflecting material....
I marked a nice spot on the shoulders.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS73.JPG

With a sling-shot drill ( my dutch translation ) I made a hole for it.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS74.JPG

The edges need some work, but be cool, I have that covered.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS75.JPG

And this is how it will look like, left and right.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_LEGS76.JPG

My friends Sting and NoTo helped me with a playlist of R2 sounds with a minute programm
called TrayPlay. With the aid of Audioconvert I made a whole lot of -empty- MP3's
with silences of 10, 20, 30 secinds etc etc. Together with the real R2 MP3s into one
large list, shuffled at random, this will give me random beeps at random silence intervals.

http://www.thebestcasescenario.com/frenkie/r2d2/Legs/R2_MP3.JPG

Made two rings for the speaker edges. Made them into large hexa shapes, to resemble a nut.
( well ..sortoff )

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY156.JPG

And here there on.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY157.JPG

The 4 UV-LEDs for the backdoor print were way to obvious in sight. So I made this:
A couple of old circuit chips....

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY158.JPG

Soldered together under about 45 degrees....

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY159.JPG

Glued them on top of the LEDs...

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY160.JPG

And this is how it looks like.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY161.JPG

A view from a distance. With the lights on, in the semi-dark this looks really good.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY162.JPG

Have been tinkering with pinstripes.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY163.JPG

AARRGHH!! When I was mounting the right leg through the body, I accidentely ripped
the wires, and I had to disassemble the whole thing. Here is how the new wires
look like.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY164.JPG

And from the front.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY165.JPG

To keep it simple ( KISS ) I used a regular audiojack to connect to the PC and let the
wire go trough the plate via the USB slot.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY166.JPG

Total of the rearside.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY167.JPG

And there he is.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY168.JPG

All lights are in working order, and the sound is quite good for such el cheapo speakers.

http://www.thebestcasescenario.com/frenkie/r2d2/Body/R2_BODY169.JPG

Gonna tidy up all the small bits that I left, paint some more here and there and finish it.

For all of you who are still here after this long worklog, I made some small movies for your entertainment.

right side

pvJBmjcruS0

left side

l1UzSQexiDo
rear
CIM43nqOeFE
one more post to go...... :)

Frenkie
03-24-2008, 11:49 AM
I'll PM you for the URLs, but I just browsed through ebay for these deals :)

This weekend (21-3) there was the T.i.M.e.S. lanparty (http://www.times-lan.nl/) here in the south of Holland. It was full again with 470 entries but only 300 seats ! I was glad to hear they had a casemodcompo, so I could take my little friend with me to see what people thought of it.
Here are some of the participants.

The radarmod from [EXC]EéVé and it really turns all the way !

http://www.thebestcasescenario.com/frenkie/r2d2/times4.jpg

http://www.thebestcasescenario.com/frenkie/r2d2/times6.jpg

The very cool Entono Xtrauma # 0137 from Warkel

http://www.thebestcasescenario.com/frenkie/r2d2/times7.jpg

He also brought his server which is also quit neat.

http://www.thebestcasescenario.com/frenkie/r2d2/times5.jpg

and the superb Shuttle from Brutus.

http://www.thebestcasescenario.com/frenkie/r2d2/times14.jpg

But this topic is about my little R2... here as co-pilot...

http://www.thebestcasescenario.com/frenkie/r2d2/times2.jpg

( You should have seen the faces of people passing by....... LOL )

And here it stands beside me at the table.....

http://clan-rag.gameparty.net/bitchie/case/12/times3.jpg

The back.

http://www.thebestcasescenario.com/frenkie/r2d2/times9.jpg

close-up of the modded circuitboard.

http://www.thebestcasescenario.com/frenkie/r2d2/times10.jpg

The jury thought mine was the best there and gave me nice cup :-)

http://www.thebestcasescenario.com/frenkie/r2d2/times1e.jpg

I made a list with some TO-DO things for the R2, but most is internal and not worth another photo.
I will start a new project ( well, actually I have enough material for 3-4 new projects ) but havent got the
time for all of them. :(
I want to end here with a big thankyou to everyone who helped me with tips, tricks, links, remarks and
critics and ofcourse new or used hardware for all my projects. Thanks Salland (http://www.sallandautomatisering.nl/), Space Promotion (http://www.spacepromotion.nl/),
Sapphire (http://www.sapphiretech.com/), Revoltec (Listan) (http://www.listan.net/listan.net/) en Zalman (Essers). (http://www.h-essers.nl/)
Untill the next project!
greetings Frenkie


Frenkie at the HME 2008 in Utrecht, The Netherlands
http://www.thebestcasescenario.com/frenkie/r2d2/tbcl2008-1.JPG

and the result; 2e with the pro-jury and first with the visitors-price.
http://www.thebestcasescenario.com/frenkie/r2d2/tbcl2008-2.JPG



Link To Original Worklog (http://www.thebestcasescenario.com/forum/showthread.php?t=13478)