Project: R2-D2 by Frenkie

[Frenkie]

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.

Lets get an old PC case from the attic.

Quickly disassembled.

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

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

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.

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

Thats off, now the sharp edges.

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

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*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.
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The back, looking good.

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

Used the dremel to cut the hole for the vent.

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

My sponsor SpacePromotion provided me with two 60 mm fans with white LEDs.

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

Bit of creative cutting.

LEGS.

A stack of MDF wood and some wood-glue.

Something like this.

First cuts.

Using the workmate and clamps the legs are taking form.

With some sanding they look now like this.

[Frenkie]

Starting chapter three; the DOME

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

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

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

And these two for the FRONT-DISPLAYS.

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

Back to chapter one, the BODY

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

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

-sorry, one photo missing here-

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

The skirt sides.

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 ? )

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

More MDF and some aluminium for the support frame.

Something like this.

Fitting in the case,

Bolted to the bottom.

[chaksq]

I like this, I think it's going to turn out great the way your going so far. Especially after seeing how The BFG turned out (whenever I see that name I think of a book about a giant of the same title). I also like how your reusing old parts to make this (the trashcan and computercase).

[Frenkie]

Made a Rader-eye holder from some MDF.

Round it off and fitted the eye glass.

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 )

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

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

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

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

The guys at Space Promotion gave me this ZALMAN fancontroller.

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

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

Does'nt look too bad.

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

Glue it with construction glue.

And there it is.

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.

Pre-drilled the LED holes.

Bended it with a heatgun until it matched the curves.

Then drilled the final 5 mm for the LEDs.

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

All LEDs in and glued.

Quite a mess eh ?

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

[Frenkie]

Made some strips of Vikureen for the rectangle parts that come into the round outerlayer.

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

Also from Space Promotion i got these Zalman harddisk coolers.

At first I wanted to mount them on the bottom.

Then decided to mount them as high as possible.

Dremel dremel dremel..... a hole !

The supports are the same as for theZalman fancontroller. ( type QeD )

Preparing the table legs for mounting.

Screw them on.

An old cilinder that used to contain wire.

Cut in half and measured it.

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

Spray painted the dome and radar-eye holder.

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

made a hole and glued it on.

From the front.

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

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

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

Started to glue the LEDs into it.

When it is on, it looks like this.

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

.....but with some UV on it.....

[tinker]

lookin really good.
The gel pen effect is awesome.

[p0Pe]

that uv gel pen is amazing!... looks REALLY sweet! +rep for a cool non expensive build

[TheGreatSatan]

Very nice! +rep, obviously...

[SgtM]

Very nice! +rep

[SgtM]