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Looks like you know what you're doing...i'm afraid i only really know about DC, not really having had to work with AC or AC/DC converters and the like. But R2 looks like he's (she? Hmm...i wonder...would explain the whining noises :eek: ) coming along great!
Sorry about that joke.
-Dave
Last night was a night of mixed emotions......
I went ahead and cut the motor mounting bracket. Here is a comparison pic of the completed (working) motor mount for the right foot and the new setup for the left foot. I just took the outer plates and flipped them over (basically turning it inside out). Looks like it will work great!
So I set to work welding the mount back together, Everything was going well when I got to this point.
As I went to weld the back of the angle I found that I was out of gas, not tired but my Acetylene tank is Dry.....So no more welding till I get it filled! I'm looking into where I can have it filled (or trade it in) here in Lansing, hopefully they will be open on Saturdays, If not I'll have to send my wife next week (she's on spring break from Vet School!).
Why did I say mixed emotions? I was really happy that the fix was going to be that simple (still allot of work but not overly complicated), and to be so close and not have the power to do any thing about it...is frustrating... But finding the silver lining, as it was 11:30pm I figured I should get some sleep and I'll start in on some of the wood and plastic stuff tonight! (that back DOOR!!! I want to get it done, and seeing as my wife told me I was going to finish the dry walling in the garage as well as rip out the old work bench Saturday. So she could finish and install the new ones over spring break, I'm not sure If I'll get time to work on R2 this weekend. Tonight will have to be door night.
Thanks for the kind words, and the support, stop back again.
Crazybillybob
I did get some R2 work done this weekend, but not much Dry walling (Had to demo the old stuff in the way :D But It will get done this week).
I was able to get the Rear door to fit in place using the plywood Arches I cut before and then running a 2" wide strip of Plywood up each side (I routed out rabbits for each arch). It fit great when I had it taped into place.
I epoxied the frame together then the skin to the frame. After the epoxy dried I pulled the tape and clamps, some of the skin pulled away from the frame (didn't use enough glue!) No big deal I'll fix it later, and I have a couple of body frame rings that will have to be trimmed back for better clearance, but I'm much happier with the fit this time! Here look for your self.
The Door work was on Sunday night. Last night I started work on one of the detail pieces. It's a vent on the side of R2 under his legs...hence it's called a side vent. I have to modify it a little bit because I want air to be able to pass through the vent (on the "Real" R2s there just for looks) but I'm not that far yet.
I started with a drawing of the piece that I had transferred to card board and cut out to make a template.
I made the template because I need 2 of these parts and easier with a template then the spray glue method I like. The Outline was trace onto a sheet of 1/8" aluminum. I'm going to go off on a tangent here, The Aluminum that I'm using here is 3001 or 3031.... IF YOU CAN DON'T USE IT. It's real soft and it gums everything up and it flexes so much that I could not cut the inside details with a jigsaw. If you're going for small details pick up 6061, I've used that on most of the other parts I've made for R2...It's some much easier to work with, cause it's just a little harder.
I cut out the slots in the plate with a 4 1/2" angle grinder (the dremel cutoff wheel just loaded up with Aluminum and bogged down the dremel) So the cuts are rough...real rough. I drilled a hole at the head and tail of each slot (so the waste strip could fall out). I would like to emphasize safety glasses again, I busted one of my 4 1/2" cutoff wheels on this and pieces of it bounced off my safety glasses, I still got some grit and dust in my eye but at least I still have an eye!
Once I got the slots roughed in, I attempted to use a carbide burr on the dremel to chew away allot of the excess material....no luck this stuff just gummed up the bur...So I when at it with some hand files. That's the only good thing about this aluminum...it files well.
Here's the part when I called it a night (1am), the top 2 slots have been filed down (there's still some light filing to do, and the corners need worked, but that work can be done in the house where it's warm)
The bottom three slots have just been touched up a little with the burr and the dremel (knocked the slag and real high spots off so they file better).
Hopefully I'll get this or some drywall knocked out tonight after work.
Thanks for stopping by,
Crazybillybob
looking good as always. keep up the good work!
Well With a little bit of Filing with my "Little" File, I've got the Slots smoothed out mostly. Still need a little work in the corners and ends.
My "Little File"
The Vent
Last week at the end of the week I got a neat surprise. I received a laser cut plastic dome ring. Thanks Andy. It's of the Same design as the wood one I made a few weeks ago.
the plastic one.
the wood one.
Now I just need to get it mounted.
CrazyBillyBob
LocalNut Job and Astromech Tech.............Part Jawa, Part Wookie
Looking good-glad you managed to save that Vent, things were looking scary for a moment there ;)
Keep it coming! How much work do you reccon's left now? From what i see you have the drive motors and most of the elctronics working, your chassis is coming along great and all your trying to work out is the mechanisms for moving the head and letting the bugger charge up, right?
Not long to go hopefully!
Oh, and my Make Magazine arrived (yay!) which got me thinking: is your R2 a 3 legged, 2 legged, or switching variant?
-Dave
Dave,
I've got allot left. Not all the electronics are done ....maybe 20% are complete. THe frame and bbody are 90% complete. I still have to etch the dome, wire the whole thing up, mount the last motor, mount the center leg (and foot shell). Then thereis the PC install...Haven't even started that. I'm probibly 60% complete with all of R2.....Big thing Is PAINT...It's gotta get warmer here some time!
This will be a fixed 3 Leged R2...I had to give up the space for 3-2-3 mech to the computer. It's cool because I've been using ILM's carbon fiber R2 as my referance, it's a fixed 3 legger as well.
Well off to work in the spice mines again!
Crazybillybob
heh - read this whole log in one mammoth session and i'm very very impressed. one of the most ambitious mods i've ever seen and also with some truely innovative things in it (the projector).
[off topic] Which vet school is your wife at? i'm in my second year here at bristol vet school [/off topic]
She's in her Second year At Michagin State.Quote:
Originally Posted by jonny_boy27
Thanks for the pat on the back.
Crazybillybob
Hello R2 Fans, Well another weekend has come and gone....And I have more progress to report (and Pics for you!). This installment of the R2Server Worklog will be Pic heavy, I had a camera women in the workshop on Saturday so there's action shots for you.
The goal of this work session is to get the panels cut into the center foot shell. The Panels allow access to the wheel and the mounting bolt for the foot to ankle connection on the center foot. So the panels need to be removable. Plus they add the extra little detail that's on the Real R2.
We start by laying out the cut. The goal is make all the black disappear.
Then Make some starting cuts with the Dremel, so I can get the jigsaw balde in and do most of the cutting. The Jig saw cuts through the sheetmetal faster then the dremel (and cheaper....I use less cutoff wheels this way). Here's what the cuts look like after the jigsaw.
The turns in the corners were to tight to get with the jigsaw, and there is not enough clearance between the steel and the channel on the top. These areas will be cut with the Dremel.
I think that's the first shot of me actualy working in this worklog :)
After some dremeling this is what you get.
And after yet more cutting.
Now the Center sections that were cut out will be reused as the panel doors. To keep them from falling back into the foot shell I made up some sills that will be welded into place.
The sills are laid out on the sheet metal and cut out with tin snips.
Now before I weld everything in It's test fit time. Masking tape is for holding things in place.
After a little heat and some Welding Rod.....
I've still gotta make the clasps that hold the panels in place yet allow them to be removed for maintenance, but this is what the shell will look like.
I've got some Ideas for the clasp just need to make one up, and test it.
Let me know what you think.
Crazybillybob
