R2D2’s Inferior Neck Mechanism:

I managed to perfectly round the body by adding a perfectly round rim with two flaps to attach the neck mechanism to. This rim was done using fiberglass and a mold I created (also from fiberglass) from a template generated using my index head on the milling machine. This is not the cleanest implementation, but the results are way better than I ever hoped for!

R2D2’s Neck Mechanism:

To the two flaps shown on the above picture, this portion attaches to (Sounded like Yoda here, didn’t I? Hmmphh?) This piece was done with fiberglass as well. However, the mold was done using a Smooth On rubber and plaster as the support.

The original piece was done in wood using my milling machine and the index head. Is the only way to get perfect roundness with these dimensions. The other option would be a lathe, but at 18” diameter, I think we are dealing with the mother of all lathes (not the one I had or will ever own).

Notice in the center of the assembly there is a very nice ball bearing with a plastic center. This is the nicest ball bearing I have ever bought. I got it on a surplus store. The guy had dozens of this but I only bought one. I returned a few weeks later and there were none. He never got any more. The lesson here? Stuck on cool items, whatever the surplus price!

R2D2’s Head With Upper Neck Mount:

The bottom portion of the head is another perfectly round rim. Notice the hole in the center of the aluminum plate. This hole fits perfectly into the plastic piece shown above. Another plastic piece is then screwed on top of the plastic center, and the upper rim is now fixed to the neck mechanism.

The only problem I experienced with this neck mechanism is that if it is tighten too much, which is necessary so that the head does not rock on the axis, then there is too much friction and rotating it is quite hard. Of course, had I used some sort of CNC machinery and the proper plans, the head wopuld have been perfect on all respects. Which is not the case with my hobby equipment.

The upper head then fits into the upper rim by two prongs I created using plastic and aluminum. It is the uggliest thing, ever, but it works like a charm, except for how hard it is to actually remove the head top from the upper rim. Which I guess is good during operation, right?

R2D2’s Feet Wheel and Motor Assembly:

This is the only mechanical assembly I kept from the same unit. By pure luck, it was just too well done to try and do another one. I did try a second version which would have been way better, had I finished it, but its complexity resulted quite overwhelming.

A 12V DC Motor (from a power window assembly) resides inside what I call the battery pack (besides the foot). Using bicycle chain and sprockets I machined into the axis, the motion is obtained. It is not the cleanest, and there is lots of play. However, it works!

R2D2’s Legs:

Both legs are identical and are fashioned with five components. The white portion of the leg, is made of plastic. It is a hollow piece I was able to make with a technique I can hardly believer I came up with. Basically I made the piece with liquid plastic poured into a mold. However, it was more like a cover. I then taped this cover with the aperture toward a metal plank and poured more liquid plastic through the center hole on the top. When it hardened, the result was a hollow piece. Very strong, by the way!

The second part is the blue portion of the leg. Still white in this picture, this piece was manufactured using the same technique as above.

The come the ankle (done as above) the battery pack (same here) and then the actual foot ( one simple cast)

R2D2 From the Inside:

This is one of the ugliest views on my unit. However, there is no need to look at this when assembled. It is a good picture to see all the fiberglass compartments I added through time. There is no way to make this body on a single run. It was run after run of different molds and gluing other parts. That is the beauty of fiberglass!