Stage 1: Inner Frame. Step 1: Design and Prep

It makes sense to start with the inner frame, since everything else builds off of it.  There were a number of options here, including a really nice aluminum frame that could be purchased.  However, the Builders Club made available some detailed templates for building a wood frame.  I'll save a few hundred dollars by  building it myself from scratch and by using wood instead of metal, I already have most of the tools I need, wood is lightweight but (relatively) strong, and wood is easiest to work with -- at least for me.

Credits: The wood frame I've chosen to build was originally designed by Mr. Mike Senna, converted to templates by Mr. Michael Davis from CAD drawings by Mr. Matthew Henricks.

Fortunately for me, I have an old large-format printer in the closet, literally sitting there gathering dust.  I was able to get it breathing again with surprisingly little trouble, and out cranked the templates.

HP DesignJet 130nr, resurrected from the dead.

These will serve as cutting guides for the wood frame.  Once printed out, everything looked good:

My assistant, Cleo, compares the templates with a reference model.

Now the only question remaining was whether it was the right size.  I took careful measurements of the templates to compare with the "official" R2-D2 design blueprints.  Also, it was time for my earlier foresight to pay off; the "Lazy Susan" mechanism, known to fit the soon-to-be-fabricated Dome, had arrived, so I could compare that to the template as well and make sure it would fit right on top.  And the verdict?

Blueprint, Cutting Template, Lazy Susan ring, and Ruler

Perfect.  The template printed at exactly the right size called for in the blueprints, and the Lazy Susan mechanism fit right on top with just enough room to spare for the dome itself.

So far, so good!  I picked up a new jigsaw and a routing bit for my Dremel, so all that's missing is the wood.  Not much longer until this build actually involves... y'know... BUILDING something!

Early Part Orders

As I mentioned in the previous post, Phase 1 (or Step 1 or Stage 1 or whatever) will be the inner framework, which I'll be building from scratch.  More details on that soon.  However, I'm also looking ahead to the Dome.

I'm just starting this project, but there are many other R2 builders deep into their own builds.  For the past couple of months, a part run (where a bunch of people get together and get a part custom-made) has been being organized for a dual-layer laser-cut aluminum dome, and there is now less than two weeks left before orders are closed and the laser gets to work.

http://www.300mmdome.com/

Time's running out, so it's decision time NOW.  This is as good as it gets; this dome will be custom-engineered to be as screen-accurate to the "real" R2 as humanly possible, including the beautiful shiny aluminum skin.  However, it's the most expensive option there's going to be for the dome.  It can be done for less using something like styrene, and styrene domes have been made that look just like aluminum.

I may end up regretting this decision later on when I look at the final cost of the project, but I'm biting the bullet and spending the money to join in on this run.  Yes, this is a lot more money than I was planning on spending so soon after starting this project.  Here's why I'm doing it:

• The Dome is an iconic part of R2, recognizable just by itself.  This isn't the place to scrimp.
• It's true that when this Dome arrives, there will still be a lot of work to be done with it; it is NOT a finished product.  However, at least a good chunk of the work IS done, thanks to the laser cutter... that's what I'm paying for.  Plus, I have the necessary skills and tools to do the rest of the work, so I don't have to learn how to work with, say, plastics.
• Plastics, again for example, have to be worked with and painted to look like aluminum.  Aluminum already looks like aluminum.
• If I DON'T go for this now, and later discover this WAS the best option, it'll be too late.  There's no telling when the next run of these highest-end domes will be.

Lee Valley 17-3/8" Lazy Susan Bearing

I also ordered one other part, but this one falls under the category of "finding a cheaper substitute".  When the dome eventually gets mounted to the frame, it needs to be able to turn/spin. This is done with a part called a "Rockler Bearing".  However, the manufacturer of the Dome above noted that a woodworking-tool manufacturer called "Lee Valley Tools" makes a mechanism for a Lazy Susan that just happens to be the perfect size to fit the dome, and yet costs a good deal less than the normal Rockler Bearing.  I went ahead and ordered one so that, as I make the inner framework from scratch, I can make 100% sure that the dome is going to fit perfectly on top long before the Dome ever arrives from the manufacturer.

Design Considerations and Planning

Cliche du jour:  Failing to Plan is Planning to Fail

I've spent countless hours pouring over information provided by the R2-D2 Builders Club to see what it's really going to take to accomplish this and how.  The process is daunting, but, like the riddle goes... "How do you eat an elephant? One bite at a time."  Translation:  If I think about the entire build at once, my brain will explode, so I just have to break this down into parts/stages/phases/whatever. 

For each step along the way, the following questions have to be answered:

• Should this part be built-from-scratch, purchased / CNC-ordered (having someone make it for me), or do I find some substitute and make it work?
• What should this part be made from?  Wood, aluminum, styrene, resin, or...?  I'm not going to try and keep it all one material, but for each decide what will work best.  Considerations are cost, weight, strength, how easy the material is to work with, availability, and ultimate appearance.

I do have some things going for me.  I'm not COMPLETELY inexperienced with building things, especially when I have some guides to go by.  I have friends -- well, friend -- who is an old-school DIY'er, who can offer advice and assistance.  I took basic Engineering courses in college (I started out as an Aerospace Engineering major before I found my true calling in Computer Science) with a healthy dose of blueprint-reading.  Plus, it's not like they sell full-sized working replicas of the little guy -- and, even if they did, they'd be big bucks I'm sure -- so, I've got the motivation to see this through.   Lastly, I have the assistance of the Builders Club, which is the only way I'll be getting through this!

More motivation... chicks dig R2.

I do have some things working against me.  A lot of the mechanical "stuff" is a little new to me... neither my IT nor my software experience had much to do with motors and servos. Like so many others, cash doesn't flow quite as freely as it once did.  I've got other commitments that cut into available time.  Plus, I've had a bad habit of diving in to hobbies but giving up after awhile (though, again, I'm a lot more motivated with this than anything I've done in ages!). 

So, I've raided the local Office Depot and made up a project three-ring-binder with page protectors and section tabs to help keep every organized... which is better than my usual pile-of-papers-on-the-couch filing system I normally use.  So, it's time to get started.  Phase 1 will be... the inner framework!  Seems like the most logical place to start.  Stay tuned!

An Introduction

Since I first saw Star Wars back in 1977, I've wanted my very own R2-D2.  However, I never thought I'd be building one myself.  Then, one ridiculously hot and humid day, having decided to get back to my geek roots, I went to Star Wars Celebration V, a giant fan-fest for all things Star Wars.

There were R2-D2s there.  I don't just mean one or two, but a room-full of perfect-looking droids.  It turns out there's a world-wide club dedicated to building them, the R2 Builders Club.  I got to speak with several of them at the Celebration, and they were all very encouraging for "newbies" to dive in.  It turns out they have mountains of information to share: detailed blueprints, suggestions, stories, part ideas... all readily available along with plenty of offers of support.

Obligatory Slave Leia Picture

So, long story short (oops... too late), I am starting construction on my very own R2-Series Astromech Droid.  I'm hopeful I can get this done within one year, but other commitments, finances, and parts availability may all play a part.  I know a guy who knows a guy who built one in just a couple of months, but even the other builders are astonished by that kind of turn-around.  This should keep me busy for quite awhile, and I'll have to learn some new skills along the way, but I am really looking forward to this.

Here I go!