tag:blogger.com,1999:blog-79884658142522856012024-03-05T00:05:39.573-08:00R2D2!!Gotta Build an R2D2, Gonna Share.Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.comBlogger127125tag:blogger.com,1999:blog-7988465814252285601.post-33045528964358304762020-07-14T10:26:00.000-07:002020-07-14T10:26:08.664-07:00PVC Battery Boxes, new designIt's proven hard to find PVC pipe with an outside diameter of 3" that works for these boxes. But I've figured out the supply problem, and worked out some building tricks that are giving me reliable results now. These are to R2 club CS:R specs and they're sharp:<br />
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-8579506499007865132017-11-28T20:52:00.000-08:002017-11-28T21:02:08.277-08:00<br />
Here are some pictures of my recent MDF Horseshoes.<br />
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-20275283648474867792017-08-25T15:22:00.000-07:002020-07-14T09:58:20.160-07:00Cutting motor ports into aluminum R2 battery boxes<br />
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I thought I'd offer some guidance here about how to cut the motor ports out of the battery boxes. <br />
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First, the dimensions:<br />
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Notice that there should be a right and left motor port, and that the port should be cut on the same end as the knurled hose fitting holes:<br />
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There are several ways you could make these cuts, depending on what equipment you have. I use the table saw, a compound miter saw, and a grinder with a metal cut off wheel to make the cuts. <br />
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I set the fence so that the cut here would be at 1" from the left edge, I clamped a stop block to the fence so that the blade would only cut to 3.5" inches into the body, and I set the height of the saw blade so that it only cuts 1.5" up. Measure twice, or three times, and don't get this wrong. For the other parallel cut, you can keep the stop block in the same place, and the blade at the same height, and just move the fence over. <br />
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For the cut on the body, I use the compound miter saw:<br />
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Again, I set a stop block on the fence. It's on the right behind the blade. It set so that this cut is 3.5" from the outside edge of the box. And I carefully plunge the blade down and in (take care, the blade can catch) until the cut just meets the other two at the corners. <br />
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For the last cut along the curved spine of the battery box, I use a metal cut off wheel on my grinder. I clamp the grinder on top of blocks to get it 1.5" off the table top. Then I carefully plunge the box into it to make the cut. This method is slower than the others but it's the best way I've got to cut the curved side of the box. <br />
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I hope that helps. <br />
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-39025794227961969272017-08-07T16:05:00.002-07:002017-08-07T16:05:42.553-07:00CS:R Aluminum Battery Boxes Fall 2017<div class="separator" style="clear: both; text-align: center;">
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Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-6171050099730953652017-06-01T10:53:00.000-07:002017-06-01T10:53:11.280-07:00Aluminum Battery Boxes prototypes<div class="separator" style="clear: both; text-align: center;">
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-42888306750243845242015-09-19T09:43:00.000-07:002015-09-28T08:52:04.780-07:00New Aluminum Battery Boxes<div class="separator" style="clear: both; text-align: right;">
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These are new battery boxes I've been building with Bennett Dahl. We've been doing R and D for a few weeks and we've worked out a method to build these out of 16 gauge aluminum sheet. The backs are attached with small, flush mount machine screws. They are built to the CS:R club specs, which are 8.25" tall and 3" wide. These are slightly oversized, usually by about 1/16" to 1/8" in height and width to accommodate the NPC motors. </div>
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They are $280 a pair, plus $20 shipping in the U.S. Shipping is $45 to Europe, Australia, New Zealand, Mexico, and Canada. </div>
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We can cut motor ports in the sides for an extra $20 per pair, but since everyone's motor setup is different, we are leaving them whole as the default. They will come standard with 5/8" holes drilled for the knurled hose fittings, but we can leave those off by request. </div>
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These are sanded down to 120 grit. A bit of sanding to 220, and then some self-etching, metal primer will get them ready for finish coats of white. </div>
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<a href="http://www.paypal.com/" target="_blank">Paypal</a> $300 for a pair of boxes (which includes shipping) to mccormick@csus.edu</div>
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Add $20 for motor ports. </div>
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Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com2tag:blogger.com,1999:blog-7988465814252285601.post-77722988675800278592015-08-14T14:02:00.001-07:002015-08-14T14:02:39.894-07:00Pictures of the new CSR Battery Boxes from A New Hope<div class="separator" style="clear: both; text-align: center;">
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-82717612937586324172014-09-22T18:30:00.003-07:002014-09-22T18:30:39.489-07:00<div class="separator" style="clear: both; text-align: center;">
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R2 Dome Travel Case for sale. $100 Email me at mccormick@csus.edu</div>
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Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-70062820675691721372012-06-01T23:40:00.000-07:002012-06-01T23:40:06.084-07:00R2 on TV in SacI took R2 to Willett elementary school in Davis for a charity thing. The cameras from Good Day Sacramento came along. <a href="http://gooddaysacramento.cbslocal.com/video/7349014-r2d2-visits-school/">R2D2 School visit</a> Until I figure out how to capture the video for myself, this link will have to do. <br />
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<br />Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-20064108470189519292012-06-01T23:20:00.000-07:002012-06-01T23:20:04.994-07:00Maker Faire 2012We had a great time with the other builders at the Maker Faire in San Mateo this year. 6 droids in attendance. Great location, lots of adoring fans. We also had the Wall-E builders, Mike Senna and Mike McMaster up from southern Cal. Thanks all for a great event: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ56_lXdjpGfNrd2vZtLY9Gc7nO9zPxu7avjIRFZlsTM6QBjxpVjilT7GE0BoTK-G2vp0sWWGDWpP9vqV68tsFR0A-5NUcOmT51k4u-VUH6t9v6_iOeEz6BsjYV2R55Jq2H42IiaAWn-dL/s1600/MF+2012.jpg" imageanchor="1" style="clear: left; display: inline !important; margin-bottom: 1em; margin-right: 1em; text-align: center;"><img border="0" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ56_lXdjpGfNrd2vZtLY9Gc7nO9zPxu7avjIRFZlsTM6QBjxpVjilT7GE0BoTK-G2vp0sWWGDWpP9vqV68tsFR0A-5NUcOmT51k4u-VUH6t9v6_iOeEz6BsjYV2R55Jq2H42IiaAWn-dL/s400/MF+2012.jpg" width="400" /></a>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-54712336603013139462011-09-27T21:25:00.000-07:002011-09-27T21:25:16.967-07:00Leg set for sale.<div class="separator" style="clear: both; text-align: center;"></div><div class="MsoNormal" style="text-align: left;">I’ve got a full set of assembled, finished and primed wooden legs for sale.<span> </span>I was commissioned by a builder to make a pair and I made an extra set for myself.<span> </span>But it doesn’t look like I’ll use them on a second droid like I planned.<span> </span>So I’m going to offer them here for cheap. These are assembled in the Senna/Franco style, although I made a number of mods to the design.<span> </span>I used high end cabinet grade plywood.<span> </span>There’s a space inside for motor wires.<span> </span>You’ll also notice from the pictures that I’ve added a flange to the back of the center leg where it rests into the center foot shell.<span> </span>This will keep the foot stable and secure and spread the load.<span> </span>These may need some minor sanding and a bit of finishing and they are ready for paint.<span> </span>There are four T-nuts mounted inside to bolt the leg to your frame which will probably need to be drilled to match.<span> </span>I’ve run a set of these on my R2 for a couple of years and lots of events with zero problems.<span> </span>Lots of details about their construction here:<span> </span><a href="http://buildr2d2.blogspot.com/2009/12/legs-finished.html">http://buildr2d2.blogspot.com/2009/12/legs-finished.html</a> and in the older posts.<span> </span></div><div class="MsoNormal" style="text-align: left;"><br />
</div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ0gziAbuKqfTp_Dm4kNxjHx3RMDlbCZtLREbEr_9J_Ryg7JGwF3oc_7yt_KYx-8ICQFyN2oglEKKMFsIS9B-4xrZyREzhb5O9u8K5rUoptWFAq2WbZw49eFQxIVuJ7QCg9iBYpSJ9EHP_/s1600/IMG_1268%255B1%255D.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em; text-align: left;"><span class="Apple-style-span" style="-webkit-text-decorations-in-effect: none; color: black;">I’ll take $575 for them plus shipping.<span> </span>Consider that a full set of aluminum legs with angles is around $1200.<span> </span></span><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ0gziAbuKqfTp_Dm4kNxjHx3RMDlbCZtLREbEr_9J_Ryg7JGwF3oc_7yt_KYx-8ICQFyN2oglEKKMFsIS9B-4xrZyREzhb5O9u8K5rUoptWFAq2WbZw49eFQxIVuJ7QCg9iBYpSJ9EHP_/s400/IMG_1268%255B1%255D.jpg" width="400" /></a><br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2arNMkBPbDxJGwY4McvUa9xWnBvNhsCMUO8PIY3ioHKYf6xxbLy1gnXxqMMnIuAOj12itYDufT31cBOqMPrTI9APM1_-0rgjwGn0SgTMDiyLk8P9Lc2baGsTV6H55ATJeibjRHo1r7mYI/s1600/IMG_1273.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2arNMkBPbDxJGwY4McvUa9xWnBvNhsCMUO8PIY3ioHKYf6xxbLy1gnXxqMMnIuAOj12itYDufT31cBOqMPrTI9APM1_-0rgjwGn0SgTMDiyLk8P9Lc2baGsTV6H55ATJeibjRHo1r7mYI/s400/IMG_1273.jpg" width="300" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjmNGrSCB9625sz7F8o3NHnfBMXlBYNnnyoXKUt5nK3kRWhv7_fmWaLwk_SULiWtn6c387sCTEkFGgpVZIIBOfG2ptojYf1w9GB_zK3kkjI_NVXxE5qF9NH8aTrACEnhtYcnGrgr5dX7cC/s1600/IMG_1272.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjmNGrSCB9625sz7F8o3NHnfBMXlBYNnnyoXKUt5nK3kRWhv7_fmWaLwk_SULiWtn6c387sCTEkFGgpVZIIBOfG2ptojYf1w9GB_zK3kkjI_NVXxE5qF9NH8aTrACEnhtYcnGrgr5dX7cC/s400/IMG_1272.jpg" width="300" /></a></div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com2tag:blogger.com,1999:blog-7988465814252285601.post-80036723723309800702011-08-27T22:32:00.000-07:002011-08-27T22:32:25.665-07:00Boba Fett ProgressWith the guidance of some friends, I've been working on getting my vacuum former working and pulling some armor pieces for Boba Fett. Made a bunch of progress today: <br />
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</div><div class="separator" style="clear: both; text-align: left;">These are the side pieces for the knee armor. I think I got the plastic too hot and the webs formed. But they'll clean up and these are usable. I'm picking it up fast. </div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: left;">Next I pulled the kidney plate. This came out better. The only part that I need is the outer curve. The rest will trim away. </div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: left;">These are the knee plates. The webs will be cut away so these came out great. I've trimmed all of these and now I just need to construct a form for the back plate and I'll have the full armor set. I was apprehensive about the vacuum rig, but this worked out ok. I'm glad. Maybe after Boba Fett it will be time for a stormtrooper. </div><div class="separator" style="clear: both; text-align: left;"><br />
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Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-28766181858407147142011-06-17T18:43:00.000-07:002011-06-17T18:43:31.245-07:00Battery Boxes for Sale<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVMKhpTrJY6e3HJjUAVvR3Z9TgDqDFKcB63RyoL2cfwlCaPtQPTf0gRDhxTzlSj2DwsxxxbRSTEQ8CK0Uwe5q35xMxYwx6E_UW31ac7u-0GyHiJv8sZlqzOVjmzSEnHc5m5AMLOGkD0tm0/s1600/IMG_1558%255B1%255D" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVMKhpTrJY6e3HJjUAVvR3Z9TgDqDFKcB63RyoL2cfwlCaPtQPTf0gRDhxTzlSj2DwsxxxbRSTEQ8CK0Uwe5q35xMxYwx6E_UW31ac7u-0GyHiJv8sZlqzOVjmzSEnHc5m5AMLOGkD0tm0/s400/IMG_1558%255B1%255D" width="400" /></a></div><span class="Apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 13px;">I'm doing another run of Battery Boxes for R2 Builders. (Lots of requests have come in since the announcement for Celebration VI). </span><br />
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<span class="apple-style-span"><span style="font-family: "Trebuchet MS","sans-serif"; font-size: 10.0pt;">Construction: The side walls, top and bottom are made of expanded cell PVC sheet (1/4” and 1/8"). The end pieces are made of PVC pipe, sliced in half. All joints are glued heavily with PVC cement. They are sturdy enough to stand on.</span></span><span class="apple-converted-space"><span style="font-family: "Trebuchet MS","sans-serif"; font-size: 10.0pt;"> </span></span><br />
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<span class="apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;">I have not put any holes in the front for the cables or the sides for mounting to the feet. If you are putting motors inside of them, the PVC is easy to work with. You'll have to check to see which motors are compatible with the 1/4" sidewalls and the reduced width of 2.9". I haven't installed NPC motors in these, but some of the previous buyers probably have at this point. I can check.</span><span class="apple-converted-space" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;"> </span><br />
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<span class="apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;">Specs: These boxes are to club specifications with one exception. The width of the boxes is about .1" shy of the 3.00" blueprints. PVC pipe with an exact 3" outside diameter is difficult, if not impossible to find.</span><span class="apple-converted-space" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;"> </span><br />
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<span class="apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;">Finishing: The boxes have been finish sanded down to 320 grit. All the joints are smooth and clean. They are almost ready for primer. They may need a bit of touch up sanding here or there.</span><span class="apple-converted-space" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;"> </span><br />
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<span class="apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;">Price: $70 a pair, plus $20 shipping in the U.S. (Lower 48). I can ship elsewhere and internationally, but email me with your postal code for a shipping estimate. </span></div><div class="MsoNormal"><span class="apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: 10pt;"><br />
</span></div><div class="MsoNormal"><span class="Apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: x-small;">You can paypal it to mccormick@csus.edu. I'll be finishing the run and shipping them out in the beginning of July. </span></div><div class="MsoNormal"><span class="Apple-style-span" style="font-family: 'Trebuchet MS', sans-serif; font-size: x-small;"><br />
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</span></div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-34224702087605092152011-05-25T07:20:00.000-07:002011-05-25T07:20:43.437-07:00Maker Faire 2011We went to the Maker Faire in San Francisco last weekend. Once again Chris James did a lot of work to organize our presentations of R2D2 there. We also had Mike Senna, Victor Franco, and Mike McMaster from southern CA come up and join us with a Wall-E booth. It was a great event. A few pictures. Grant Imahara from Mythbusters stopped by our booth along with Don Bies (another droid wrangler and builder from Lucasfilm). <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXB834OYf3GNAtM7MZ_t3Qi9Tq2U91DlhAI9oAqThPOhcpw6BLJf0ugSnlb5Sx9n6lmwSDtvaxJiKnr2qHGRng5kCcsGUjacLK5G6lM6QX6X-pZ6qet8LVIsiaIZATQGhPGn5s6tMgVokE/s1600/IMG_0469.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXB834OYf3GNAtM7MZ_t3Qi9Tq2U91DlhAI9oAqThPOhcpw6BLJf0ugSnlb5Sx9n6lmwSDtvaxJiKnr2qHGRng5kCcsGUjacLK5G6lM6QX6X-pZ6qet8LVIsiaIZATQGhPGn5s6tMgVokE/s400/IMG_0469.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgu8Ct2ghaTivqtalehBDh5C4a4rcTUEAvkFOGGhxZjfhnMYji4BnOMJKH275EFMurY4JdZEL3YE1qAuMDTh1a2hcumckAZi0Z1VA3ZNxAuRZ2ZDGstalMQH7V6DAWL159lf593rVjuY14J/s1600/IMG_0402.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgu8Ct2ghaTivqtalehBDh5C4a4rcTUEAvkFOGGhxZjfhnMYji4BnOMJKH275EFMurY4JdZEL3YE1qAuMDTh1a2hcumckAZi0Z1VA3ZNxAuRZ2ZDGstalMQH7V6DAWL159lf593rVjuY14J/s400/IMG_0402.jpg" width="300" /></a></div>Max spent hours helping out in the bubble booth creating enormous bubbles for the crowds. <br />
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</a><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx6227v0-2yb94OibPWALvKmSjrl3eyo3rcgYNRDWZV4kCbzqfC2dgkkIJ_LxwRkGV9xdM0haSPUNkB_YoMKuXBr5PmV1HnI8qaR_JxUSqSfQ8QvWOhTED934qyacdP9AYLR6NwvT5kqtW/s1600/IMG_0320.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx6227v0-2yb94OibPWALvKmSjrl3eyo3rcgYNRDWZV4kCbzqfC2dgkkIJ_LxwRkGV9xdM0haSPUNkB_YoMKuXBr5PmV1HnI8qaR_JxUSqSfQ8QvWOhTED934qyacdP9AYLR6NwvT5kqtW/s320/IMG_0320.jpg" width="320" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2rLbfBc0aYPkpCe-fJAqSYlNMRzz7OnPdMBDiQLyofh8uMOipnf_9geuK3day09pS3nCkN-OSwZu0gdr1Xiu7EQdWD9S1dWmtLclRubMKNdufKtW2w-Dfqu1dmHSau85f82T7DvtQF4gC/s1600/IMG_0332.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><br />
</a>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-31669901620731486622011-04-01T22:33:00.000-07:002011-04-01T22:33:12.291-07:00Wonder ConThe Bay Area R2 Builders are headed to Wonder Con in San Francisco at the Moscone Center tomorrow. We've got a panel discussion on Sunday at 12:30 in room 220. Please come by and see us. We'll also be roaming the convention. The San Francisco Chronicle wrote up a story about us and the convention here:<br />
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<a href="http://www.sfgate.com/cgi-bin/article.cgi?f=/c/a/2011/04/01/DDAC1ILQBP.DTL">R2-D2 Makers an attraction at Wonder Con in S.F.</a><br />
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I'll post pictures soon.Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-21636270036044410862010-12-14T21:22:00.000-08:002010-12-14T21:22:05.005-08:00Gauntlet progressOnce I got the curved pieces formed for the gauntlets, I went to work building up the rest. Here's where I am with the left one at the moment:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSIPxabtfy0XNjjRLxwTKXrWvSM1ALAbO6syt7QDa3IKVobctU_o7JKg3u0XP_0c8pXfSMdNn6zv2OkHWWxtXZSd00bmRRCj77X9o0FSEzeB8ouA_opqXKvl-ms3kRlrh16uWjPHRHlW4b/s1600/Gauntlets+012.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSIPxabtfy0XNjjRLxwTKXrWvSM1ALAbO6syt7QDa3IKVobctU_o7JKg3u0XP_0c8pXfSMdNn6zv2OkHWWxtXZSd00bmRRCj77X9o0FSEzeB8ouA_opqXKvl-ms3kRlrh16uWjPHRHlW4b/s320/Gauntlets+012.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDvMNq-jEoCubxBrs0NZGkK3u90sC36s_PCVZUvE8einvgQAGMYvxu6ltUemhxu5v9lHeqcfO3jOCwlFpPlbSroCvroxCY6cors2aLSxdYR8LF6rH8Lc_H8DYeFw6RrK1OVTIN-bcTtud0/s1600/Gauntlets+011.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDvMNq-jEoCubxBrs0NZGkK3u90sC36s_PCVZUvE8einvgQAGMYvxu6ltUemhxu5v9lHeqcfO3jOCwlFpPlbSroCvroxCY6cors2aLSxdYR8LF6rH8Lc_H8DYeFw6RrK1OVTIN-bcTtud0/s320/Gauntlets+011.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip0Rl69VIfIPbmu3SdQtPszOKkFBuLE_6sir2FGivtPwMbSW7cigso1adrVg0Lr8SRxjDCEOUmlvi374zfR1CQHpevFyBPomRdK913I0_CSqpPO6YPD6qiQ9D4QPIY8zDRqjEGl25qntex/s1600/Gauntlets+009.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip0Rl69VIfIPbmu3SdQtPszOKkFBuLE_6sir2FGivtPwMbSW7cigso1adrVg0Lr8SRxjDCEOUmlvi374zfR1CQHpevFyBPomRdK913I0_CSqpPO6YPD6qiQ9D4QPIY8zDRqjEGl25qntex/s320/Gauntlets+009.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">This is a little rough to look at now, but it's all coming together. I'm going to have to mess around with the underside by reshaping it. I also think I'll take the inside layer out and add some thin styrene to make it less bulky. All these little pieces were cut and glued together with PVC glue. Once I cut out the templates and taped them together into a 3-D model, I could see what the overall shape and relationships were. That made cutting and building decisions a lot easier. It looks like the right gauntlet will be a bit easier. And after these, the armor should be a lot easier. </div><div class="separator" style="clear: both; text-align: center;"><br />
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</div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-32148225416754864972010-11-22T21:21:00.000-08:002010-11-22T21:21:37.663-08:00Boba Fett 2 GauntletsI took some time over the weekend to make up some forms for shaping the pvc expanded cell board for the gauntlet base pieces. There are curved pieces that wrap over the top and bottom of the forearm that have a bunch of stuff attached on top. Wizard of Flight has some curve guides for them. I transfered the curves onto some pieces of plywood, cut them out, mounted them, and then wrapped them with some card stock. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7jAgJp6BvlM_MkOmK0-x8nVuhpjuDlJ7ggrSQn78_v0bof9ARCkJntjpn4jViEAbCoXQPTjvSdHstGhe4FeVjPmT2HZYKCq5MDz8NG5v233xKa5BRFXb9TtYxI-nvSsJ5HVBAmZjeSHmV/s1600/gauntletts+003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7jAgJp6BvlM_MkOmK0-x8nVuhpjuDlJ7ggrSQn78_v0bof9ARCkJntjpn4jViEAbCoXQPTjvSdHstGhe4FeVjPmT2HZYKCq5MDz8NG5v233xKa5BRFXb9TtYxI-nvSsJ5HVBAmZjeSHmV/s320/gauntletts+003.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEQa9WUsMzbyI6hQ-yWjlDnv90a2oXa3P8u-1hryZFi4kIrDg8Nwmd2DF7AjdIIGsSjerILuSlSWRSg1nRF4J6CPbxHpN0Wc0uYVVZQOjrT_Th8sIttnVu_WPmTlAj38niNRRj9u3YgCs1/s1600/gauntletts+004.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEQa9WUsMzbyI6hQ-yWjlDnv90a2oXa3P8u-1hryZFi4kIrDg8Nwmd2DF7AjdIIGsSjerILuSlSWRSg1nRF4J6CPbxHpN0Wc0uYVVZQOjrT_Th8sIttnVu_WPmTlAj38niNRRj9u3YgCs1/s320/gauntletts+004.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Then I cut out some pieces of board slightly oversize to the plans. When you heat this stuff up, it tends to get some irregularities and curving at the edges. So I figure I'll get the curve in there and then cut them to size, square them up on the belt sander, and clean them up. That way I can be sure to cut the piece from the section that has the right curve. I got a big pot of water to a full boil, then I dropped the pieces in one at a time. It only takes 30 seconds or a minute for them to get floppy. Then with some gloves, I put the pieces over the form and shape them down to fit. As soon as it cools, it holds the shape:</div><div class="separator" style="clear: both; text-align: left;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAp1Kq5GjnFZ93w71w29ckakX6ifyo0aq58Wtv4LF6xV_eX3CT6T9WckEYsNYS2vMmZUU07irdSFZVxuzNhbc4BNBS9SnsVp1iWSzL5vr9YaG_weBKb4XgdZbi166QmXNK5QJTofn6pmsQ/s1600/gauntletts+007.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAp1Kq5GjnFZ93w71w29ckakX6ifyo0aq58Wtv4LF6xV_eX3CT6T9WckEYsNYS2vMmZUU07irdSFZVxuzNhbc4BNBS9SnsVp1iWSzL5vr9YaG_weBKb4XgdZbi166QmXNK5QJTofn6pmsQ/s320/gauntletts+007.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Cool, huh? Don't worry. These are oversized on purpose, and they are supposed to have some slightly different shapes for the assemblies that attach on top. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">I got to thinking about these after I made them. These are 1/8" thick. There's another piece that double over the tops of these with some cut outs. So that'll be 1'4" thick total. That's too thick and cumbersome, I think. So I found some 3/32" thick stock in my pile in the garage. As soon as I have time, I'll redo this in the thinner stuff. Eventually these will be painted and weathered to look like they are metal underneath. </div><div class="separator" style="clear: both; text-align: center;"><br />
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</div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-69672758295410919652010-11-11T09:08:00.000-08:002010-11-11T09:10:55.186-08:00Boba Fett 1So I've been scheming about building up the full Boba Fett costume for a long time. I actually started in earnest on it before Halloween. I tracked down a Sgt. Fang helmet. I'll post more about that later. The particular pull from the mold that I got from him has a lot of problems and will need a lot of work to make it right. I'm pretty disappointed after all the raving about Sgt. Fang and the Mystery Helmet on <a href="http://www.thedentedhelmet.com/">The Dented Helmet.</a> But for now, I've been gearing up to work on the jetpack, the gauntlets and the other hard goods. Jetpack first:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQHr4fhh2ddjq3OnpgePOuVr3AnVC9t94qQB-XcMjRJuS_A_mvd4k3kTckjB7X3HSEF6QwUrkxTyTqINNsToxmEksUqLZW6W2XZwwTmvpLfEyqbuKbqYICGdRCdAaikiusZzu-Pjfnar1Q/s1600/starwars-boba-fett.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQHr4fhh2ddjq3OnpgePOuVr3AnVC9t94qQB-XcMjRJuS_A_mvd4k3kTckjB7X3HSEF6QwUrkxTyTqINNsToxmEksUqLZW6W2XZwwTmvpLfEyqbuKbqYICGdRCdAaikiusZzu-Pjfnar1Q/s320/starwars-boba-fett.jpg" width="320" /></a></div>Scratch built Boba Fett has to start with the great set of drawings that Wizard of Flight has made available on The Dented Helmet. Look for the sticky note links under the forums for the different parts of the costumes.<br />
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I downloaded all the plans and spent a while playing around with the pdf printing variables to get them the right size. WoF drew the jetpack at 15" wide. At the time, I think that was his best estimate of the actual width of the jetpack from lots of reference pictures (also posted on The Dented Helmet in the galleries.) I've decided to scale the jetpack up a bit to about 16.25" Two reasons: 1. I'm a taller guy (6'2") than the Boba Fett actor, and 2. some new pictures and some careful sizing makes it look like the real thing is bigger than 15". Even WoF seems to agree now, but he hasn't changed the official drawings yet. <br />
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Another challenge is getting the pipes that serve as the rocket thrusters and tanks the right size. To keep the project cheap and light, scratch builders go with plumbing supply PVC pipe. So I'm using 2.5" inside diameter pipe for the outside tanks and 4" I.D. pipe for the main tank. These are both really close to the sizes on the originals as far as I can tell although WoF has the middle tank a good bit smaller. So using readily available pipes requires tweaking the plans some more. Here's where I am now. I've got a number of the main pieces cut and fitting together with screws:<br />
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</div><div class="separator" style="clear: both; text-align: left;">I went to <a href="http://www.interstateplastics.com/">Interstate Plastics</a> in Sacramento and bought some expanded cell PVC foam board. This is the Sintra (trade name) that guys are talking about on the boards. A sheet of 4' x 8' .25" board is about $50. I also got a lot of 1/8" pieces for a great piece out of their scraps bin. I can't say enough good things about this stuff. I used a lot of in on the R2. It cuts easily, the edges clean up, it can be painted. It's lightweight and easy to work with. You can heat it up, bend it, and it will hold the shape. You can glue it and create really strong joints with standard plumbing pipe PVC cement. It's just about the ideal material for prop building. I got enough to build several jetpacks and the gauntlets. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">The back of the jetpack or inside curves across both the X and Y axis. So I used a thinner piece (1/8") there and I've just temporarily screwed it together for fitting:</div><div class="separator" style="clear: both; text-align: left;"><br />
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</div><div class="separator" style="clear: both; text-align: left;">WoF's plans appear to be different from the real thing at the bottom here. On the screen used jetpack there's a recessed box. I'll be mocking that up and adding it. It'll be more detail and work, but not difficult. Once I've got all the modifications on these basic pieces sorted out, I'll be gluing all of these up. That'll add a lot of strength and integrity to the whole thing. The goal is to have it be tough, durable, but lightweight. I'm also going to cut some big pieces out of the pipes where they are hidden under the pack housing. That'll shave some more weight off. More soon. </div><div class="separator" style="clear: both; text-align: left;"><br />
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</div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-18560484357484812292010-10-31T21:50:00.000-07:002010-10-31T22:10:20.509-07:00Halloween 2010Built a lot of props for Halloween this year, including a Road Warrior costume. <br />
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</div><div class="separator" style="clear: both; text-align: left;">I used a set of football pads off of Ebay, added some spikes from some Goth Halloween store accessories. The crossbow is a cheap pistol version that I sawed off and mounted to a shin guard. I also got a set of catcher shin guards, modified them, added mounts for crossbow bolts. I made arm and elbow guards from shin guards. I used a handful of leather belts got cheap from a second hand store for straps. The torso armor is a rubber walkway carpet protector from Home Depot. The rabbit skins came from the Internet. I added some fake bones and teeth, painted to weather them, from the Halloween store. Then there's the mohawk with some temporary red dye. A black feather boa worked for the trim around the neck of the football pads. I painted everything flat black and weathered it with brown and grey acrylic paints, watered down heavily. The boots are some SWAT boots I already had. And I got a military issue gasmask at a Halloween store, painted the filter bright red. I also modified some old filters on my paint and fume mask and wore that. And I had a pair of industrial looking goggles that went over my glasses. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">I put together several other things for the Harrison's Halloween party and for our house. Today I had a bit of time and I threw together a rough Gonk Droid from stuff I had in the garage. Another day of work on it and some paint and I think it will look pretty good:</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4R_XV6KNQT-F_GrGYpu_0ahDcUbNb8AHvesOmFFOa7uo4p_I-pRXNsyfSDo0vGoB_eS2BKaw_v2CPgpFKSvGONPRTqaaRmdQPPzVj8aoGxOBASLLB0T-13AxcR_IcYG1PmLU_dBYh-OPg/s1600/Halloween+2010+370.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4R_XV6KNQT-F_GrGYpu_0ahDcUbNb8AHvesOmFFOa7uo4p_I-pRXNsyfSDo0vGoB_eS2BKaw_v2CPgpFKSvGONPRTqaaRmdQPPzVj8aoGxOBASLLB0T-13AxcR_IcYG1PmLU_dBYh-OPg/s320/Halloween+2010+370.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: left;"> There are two 18 gallon tubs, a 9" baking pan, several scrounged parts screwed into the pan, and some simple 2x4 legs and feet with dryer vent hose over the posts. This needs a lot more work but it was a good quick start on the project. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYr-jLrdduu95x7Xf2KP2vFdjsZh3dki2wNekeGMSD25mvL2k7CU58PDUjC1u47yDuXjdX0LYZgn-6Eh6t3iPOtTt0YlztYJ_sgeZG6GmR-bDbXmv2RgSeQYzWlkYkvGrmL_3V2FIqb8SS/s1600/Halloween+2010+282.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYr-jLrdduu95x7Xf2KP2vFdjsZh3dki2wNekeGMSD25mvL2k7CU58PDUjC1u47yDuXjdX0LYZgn-6Eh6t3iPOtTt0YlztYJ_sgeZG6GmR-bDbXmv2RgSeQYzWlkYkvGrmL_3V2FIqb8SS/s320/Halloween+2010+282.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: left;">I should also mention that I recently did a little event at a local Gamestop when The Force Unleashed II came out. </div><div class="separator" style="clear: both; text-align: left;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN8Ia2Az5Kys3BpAg1wRCPOywQSM7RPLzVbiTjVwLjMtHPQ7SWmByRw2Mn-MzP4W0zeZFynskP-Q_kFyTcB7fD6590lnkOBBEmOg_eT9HSkbsoSS50LHCgk-rVEJOHGpFcx_hSMsQRmxbG/s1600/Halloween+2010+284.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN8Ia2Az5Kys3BpAg1wRCPOywQSM7RPLzVbiTjVwLjMtHPQ7SWmByRw2Mn-MzP4W0zeZFynskP-Q_kFyTcB7fD6590lnkOBBEmOg_eT9HSkbsoSS50LHCgk-rVEJOHGpFcx_hSMsQRmxbG/s320/Halloween+2010+284.jpg" width="240" /></a></div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-41877450400034278622010-10-05T21:06:00.000-07:002010-10-05T21:06:54.679-07:00Update on Hammer and ObeliskI managed to get these both painted and weathered. Both are coming along nicely and will be ready for the Halloween party. I'm pretty sure that I'll need to whomp some kids with the hammer before that. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvdjFUixPrwSNJxKCzgVf_H5waJSqAlXbh-Jtw5PnQaror9cjmgS_Y__DKioJaeazmzCw7ckO7dj82uHj7bIMz1_t9x8KQtofnjgD9wok01CzVKjO54CLcS_130xXdSVkdaUMWB6tjdmTR/s1600/Halloween+2010+010.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvdjFUixPrwSNJxKCzgVf_H5waJSqAlXbh-Jtw5PnQaror9cjmgS_Y__DKioJaeazmzCw7ckO7dj82uHj7bIMz1_t9x8KQtofnjgD9wok01CzVKjO54CLcS_130xXdSVkdaUMWB6tjdmTR/s400/Halloween+2010+010.jpg" width="300" /></a></div>I've put a piece of real oak laminate that I had in the shop around a piece of 2.5" pvc pipe. I tried a smaller pipe that gripped better but it was too out of scale with the hammer head. I'll be putting some faux metal straps around the body of the head, and some metal caps and bands on teh handle. <br />
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I bought some leather straps and I was going to wrap the handle, but this wood grain looks so good on its own I might leave it. Notice the little spikes on the top. Maybe they need to be bigger, and I probably need a pair on the bottom too. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW6FSc6SDjffRJycclIzq0V7HJqJD83NkGRiQMxsWh2uczG-JzD5340xiP2W0wzjIHR_SW6rKmhgpgBdr6_UQRsOwZQGRa8zRBTj4n82TAe7sNNAaIuWDlMlILmyzQj_yx6oI3Fiby-W6_/s1600/Halloween+2010+012.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW6FSc6SDjffRJycclIzq0V7HJqJD83NkGRiQMxsWh2uczG-JzD5340xiP2W0wzjIHR_SW6rKmhgpgBdr6_UQRsOwZQGRa8zRBTj4n82TAe7sNNAaIuWDlMlILmyzQj_yx6oI3Fiby-W6_/s400/Halloween+2010+012.jpg" width="300" /></a></div>I got this all screwed together and I got the wonky top adjusted and attached. Then I hit the whole thing briefly with the orbital sander to clean up the seams. I put some filler into the screw holes and dings. Then I primed it with some latex primer I had laying around. Then a coat of gray, and two coats of weathering--watered down black acrylic and watered down burnt umber. But I don't love the finished look. It may need to be a different base color like a sandy desert tan, and then weathering over that. <br />
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I have been toying with the idea of etching some heiroglyphics on two sides in a column and then cutting them out. Then I could put a light inside to illuminate them from inside out. That would look cool, but I don't know if I"ll have time to do it. Otherwise, I think Alex and Candace may just paint some glyphs onto it.Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-5161890390512078982010-10-03T22:14:00.000-07:002010-10-03T22:14:01.157-07:00Sac Sci Fi Con 2010<div class="separator" style="clear: both; text-align: center;"></div>Took R2D2 to the Sacramento Sci Fi/Horror Convention a couple of weekends ago. Website here. Made the rounds, saw a lot of 501st members, some Mandalorians, and others. Ed Wamser was there with his R2D2 too. <br />
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Sam's getting over his trepidations about The Empire. Thanks to Myke Soler for being so friendly. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLQcNNXu5JIQOiFp0u3Ppvv5xen2sjCXeDw33cszxib8HTo9CBpZ5miJgokmSY6h4GkEHw6yIMTUR8lyG5PVXSDWeRcobUqiWyb9NfepcCfNfqlgdQ5ubI0_TAkc9JLWym7GRshgySWzJm/s1600/DSCN2221.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLQcNNXu5JIQOiFp0u3Ppvv5xen2sjCXeDw33cszxib8HTo9CBpZ5miJgokmSY6h4GkEHw6yIMTUR8lyG5PVXSDWeRcobUqiWyb9NfepcCfNfqlgdQ5ubI0_TAkc9JLWym7GRshgySWzJm/s320/DSCN2221.jpg" width="320" /></a></div>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0tag:blogger.com,1999:blog-7988465814252285601.post-11740805341760467352010-09-25T12:54:00.000-07:002010-09-25T12:54:45.972-07:00Egyptian Obelisk and Thor's HammerSome friends are having a big mythology themed Halloween party this year. I signed up to help with some props. Today I got started on the Thor's Hammer and the Egyptian Obelisk. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU3pyQHw-1U-k28BTI6Tc0ygmAnxdSF4tPEEbwzP6nJePQIBjDVEl2uTUe81EInKE31yyv_ZpjfcaFp4n5fWQ-6GchJGbocvuDjMRV2Ui5thCKGgpmb9_qPTTtYonS9adLUanSLKtN2SHI/s1600/Halloween2010+010.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU3pyQHw-1U-k28BTI6Tc0ygmAnxdSF4tPEEbwzP6nJePQIBjDVEl2uTUe81EInKE31yyv_ZpjfcaFp4n5fWQ-6GchJGbocvuDjMRV2Ui5thCKGgpmb9_qPTTtYonS9adLUanSLKtN2SHI/s320/Halloween2010+010.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwKPBl0YmZCKzQNbP72TKI4dAnEZOlHgIgwijzOuHgEGZlH9L8Uky10YMQdAM-y7VDkudQ3xr0BgxAg4f5FHEFRl8RxrSOWZPw3ALdMHxRhabjpsfjiEAIckK4HHpHDXsw3BjP0WiHNGM4/s1600/Halloween2010+013.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwKPBl0YmZCKzQNbP72TKI4dAnEZOlHgIgwijzOuHgEGZlH9L8Uky10YMQdAM-y7VDkudQ3xr0BgxAg4f5FHEFRl8RxrSOWZPw3ALdMHxRhabjpsfjiEAIckK4HHpHDXsw3BjP0WiHNGM4/s320/Halloween2010+013.jpg" width="240" /></a></div>I cut four of these trapezoids and then nailed strips onto the inside edges of two of them. The brad nailer made fast work on that part. Then I nailed the remaining two sides and put them all together. <br />
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Next I put some triangles together to make the top. Same technique, but I had to bevel the inside nailing strips. <br />
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I put that all together just loosely. The top cap doesn't fit well, so I'll probably have to work on that some more. I also cut out and assembled a quick square box for a base for the whole thing. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8_ktm4IBNHx8Q17Y-kns3qXmgHKJYrHj4TIlqcjph_3PHAdX1XSSHyVvfDpkfQS0aXA5cjm1uTTMNRWM-0y-GMmkYYFhzfPMnOyhz6feTLDe2tNAvd3m01ffpkXl4lZXANS2BClnN9uq1/s1600/Halloween2010+015.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8_ktm4IBNHx8Q17Y-kns3qXmgHKJYrHj4TIlqcjph_3PHAdX1XSSHyVvfDpkfQS0aXA5cjm1uTTMNRWM-0y-GMmkYYFhzfPMnOyhz6feTLDe2tNAvd3m01ffpkXl4lZXANS2BClnN9uq1/s320/Halloween2010+015.jpg" width="320" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbYGq9q-vSEafj9lrL3_GqMwU4-TbUPe7k2JPehDz1dnyw5zDZqWLf4X-pTDjJFeez3mMgNZOmT3WRpvBjFSMwmUHfLBRt0tfsi1UvmFKTnEQ6lwpXIZPdRju8zRTsUE3q2bnP6lSU2tiM/s1600/Halloween2010+017.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbYGq9q-vSEafj9lrL3_GqMwU4-TbUPe7k2JPehDz1dnyw5zDZqWLf4X-pTDjJFeez3mMgNZOmT3WRpvBjFSMwmUHfLBRt0tfsi1UvmFKTnEQ6lwpXIZPdRju8zRTsUE3q2bnP6lSU2tiM/s320/Halloween2010+017.jpg" width="240" /></a>Pretty cool for a couple of hours work. I'll get these all attached and get the edges cleaned up. I think I'll make a mount on the base so that the obelisk slides down onto a dowel or something so I can take it apart easily. Then I'll prime it all, paint it, weather it, and put some Egyptian heiroglyphics on it. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrceTv2Vn5KiEsUxH1YIEUvfnUba7CrjCNUxWo2X3-hmCoXsVtjg5oaBDnLvQ3gLx7Wxqx1u3YIzdjwVBtiFzBFn1ZCQoAHr8VO_ckZ3zmuzwU3zhVpmTbs0HnkYMeJb7N6MRgkUXXJ-dj/s1600/Halloween2010+001.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrceTv2Vn5KiEsUxH1YIEUvfnUba7CrjCNUxWo2X3-hmCoXsVtjg5oaBDnLvQ3gLx7Wxqx1u3YIzdjwVBtiFzBFn1ZCQoAHr8VO_ckZ3zmuzwU3zhVpmTbs0HnkYMeJb7N6MRgkUXXJ-dj/s320/Halloween2010+001.jpg" width="320" /></a></div>Next up I glued several 16" by 30" pieces of 2" foam together for the giant hammer head of Thor's Hammer. Once the glue has set on these, I'll sculpt out the hammer heads, put a 2" pvc pipe handle on it, and paint it. Should be very effective for smashing Halloweenies when they come to the door. I'm going for a GWAR look.Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com1tag:blogger.com,1999:blog-7988465814252285601.post-80748822775932492202010-09-24T17:25:00.000-07:002010-09-24T17:27:34.025-07:00Death Star Platform is finished.I haven't posted in a while, but I have been working on a few things. The platform is finished now:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvUGyMwwRpEwyXsl6tl3fMoNzQuPMH1BU3CbP6ahHaiIWBiPO1Fm0Mw2E3Es3khRqk_idKFZBJzUOb-4lrQwhhyFzW2QexqI3QkrTh5Sj5hhjS3CMNV0qv2E6maqvcCrzz7a5WO7nAKIRu/s1600/Finished+001.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvUGyMwwRpEwyXsl6tl3fMoNzQuPMH1BU3CbP6ahHaiIWBiPO1Fm0Mw2E3Es3khRqk_idKFZBJzUOb-4lrQwhhyFzW2QexqI3QkrTh5Sj5hhjS3CMNV0qv2E6maqvcCrzz7a5WO7nAKIRu/s400/Finished+001.jpg" width="300" /></a></div>You can see that I trimmed down the overall size from before, and I painted it and got the light panels done. It's 36" wide, and 40" from the front of the curve to the back edge. The curve is just an 18" radius circle. And it is 5" tall. I tried several other sizes and played around with the proportions, but this definitely looked the best given R2's size and foot print. <br />
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I primed it with the latex house primer I had around and then I put 2-3 coats of a Gloss Smoke Gray enamel on it with light sandings to 220grit in between. That gave it a very glossy smooth finish. I also filled and sanded all the counter sunk screw holes and everything else to make it seamless all over. It's very cool looking in person. I think I might put a timer on the cord to have the lights come on for an hour or two each night. <br />
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The top deck is 1/2" MDF. I drew the curve and then cut it with a small straight bore bit on my router and a circle guide/jig on the router. You could do it on a bandsaw with a circle jig, or even with a jig saw and then some careful sanding to even it out. Email me for more details about circle jigs on the router if you want. After I cut the basic shape, I flipped the deck over and using a bearing guide on my bit, I routed a 1/8" deep by 1/4" rabbet or channel around the edge. I cut a long piece of 1/8" fiberboard for the front and side faces. This wrapped around the base and fit into the rabbet. When I glued it on, the channel made a good strong bonding surface with hardly any seam where the edge piece meets the top deck. Sorry no pictures to make that clearer. <br />
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I drew 10" x 2 1/8" oblong cutouts on the edge piece, with the occasional full circle thrown in. I used a hole cutting bit for putting new door handles because it was handy and the proportions are right. That's the 2 1/8" circle, and you've probably got one of those bits around. Make sure the bit is sharp and cut straight down and cleanly into the fiberboard to minimize clean up. Once that edge piece was all cut out and glued onto the main deck. I flipped it over and glued the light diffuser plastic panels on the inside. This was a piece of plastic from the lighting section of the hardware store. I cut 4.5" strips of it and then glued them into the inside with some epoxy:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpOM80ZmywfOFl25VyNEYsI-GtBT5sniMstbYZjgA6p4V1YL0lpGsG5M20Pbm-HaqqHMRbuHm6CqK6pevOic96IDKZcJ4zYMzsJ0WpKteylsmbdeZDOUr1K7QME3VyNyLmaANd1h5af3Ok/s1600/Finished+011.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpOM80ZmywfOFl25VyNEYsI-GtBT5sniMstbYZjgA6p4V1YL0lpGsG5M20Pbm-HaqqHMRbuHm6CqK6pevOic96IDKZcJ4zYMzsJ0WpKteylsmbdeZDOUr1K7QME3VyNyLmaANd1h5af3Ok/s400/Finished+011.jpg" width="400" /></a></div><br />
There's no need to be tidy or too careful here. I just made sure that the plastic panel laid down flush to the inside of the fiberboard so that no gap shows from the outside. I clamped these in while the glue set up. <br />
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The general look I was going for was this kind of Death Star corridor.<br />
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My recollection was that there were full circles interspersed in with the oblong cutouts in these light panels. But looking at this shot, I may be wrong. There's an oblong and shorter cutout at the bottom. But nothing like the full circle I put into my pattern. I thought I had seen that on some Star Wars set. <br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-RgQYI_8Fb0lrax_ZmIgo0s28-uQ8VPuwWP_GZeMtbnrs5dZuFYTiWAcuS1Gn2MmdVdByn_hSvgQ8TBjD1rmyj3qV3ntTEVsOXTJfBA6o5CInL29adiyKZvtR7NWMc74GkATt85D8X9is/s1600/Finished+003.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-RgQYI_8Fb0lrax_ZmIgo0s28-uQ8VPuwWP_GZeMtbnrs5dZuFYTiWAcuS1Gn2MmdVdByn_hSvgQ8TBjD1rmyj3qV3ntTEVsOXTJfBA6o5CInL29adiyKZvtR7NWMc74GkATt85D8X9is/s400/Finished+003.jpg" width="400" /></a></div>The lights were a bit tricky. You don't want any regular incandescents in there because they'll be too hot. LEDs aren't bright enough. I settled on some relatively cheap flourescent fixtures from Home Deport. It's hard to find anything shorter than 18" that's cheap. I wanted them simple, with one bulb, no extra covers, and not very bulky. <br />
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The lights were about $17 a piece<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCRXqullsynI0hI-rfimHQme1Hh_jhpSq-XICyhDjp0Lvxuy0Yxk5Sy58uvD5fj0CXTuKbi7EBXw4qcqyyq4xnEWhF4N9Jw6HcXZ0bnlrs1ko2I_f4chCu1RMXz5nWX_5HRRWKPaTDmB3f/s1600/Finished+008.jpg" imageanchor="1" style="clear: left; display: inline !important; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCRXqullsynI0hI-rfimHQme1Hh_jhpSq-XICyhDjp0Lvxuy0Yxk5Sy58uvD5fj0CXTuKbi7EBXw4qcqyyq4xnEWhF4N9Jw6HcXZ0bnlrs1ko2I_f4chCu1RMXz5nWX_5HRRWKPaTDmB3f/s400/Finished+008.jpg" width="300" /></a><br />
Originally I thought I might need four short ones, with one for each chamber between the cross members. But I couldn't find them short, cheap and powerful enough. Here I just cut some cutouts into the cross members (1/2" plywood) so the lights can go right through them. I tried two light, but it was too dim and there were dark spots. This configuration works pretty well. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKT7PYwae2pbXaC9PsXg69WMN7T9zzv8GKzj5SsU0y7oJzfafMse93SA8CaYHZBpA1au36gKLX1DFVvWIeD0mB4JbtsLqT9OQmhLRjlxOhhM-L4Cwvfh3rOP7lmW-5n_jMRgc45pM7bOq-/s1600/Finished+007.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKT7PYwae2pbXaC9PsXg69WMN7T9zzv8GKzj5SsU0y7oJzfafMse93SA8CaYHZBpA1au36gKLX1DFVvWIeD0mB4JbtsLqT9OQmhLRjlxOhhM-L4Cwvfh3rOP7lmW-5n_jMRgc45pM7bOq-/s400/Finished+007.jpg" width="300" /></a></div>And a closer shot here. To attach these, I just put a screw right through the fixture body and into the bottom of the deck, without going through to the top of the deck:<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvi2Pd2QOBb8Bcfd9JXRR4FuRf488wd0ELMu8Ks54xEsK2iLa49suwvkEwhyAbdLDa1ksUMsw8jkFztaJpeGUdo1dVNxrEnmaxQo69fp_67Dza-2iNrcy5JnlLnfV26Btb-bhIuZFtEZce/s1600/Finished+009.jpg" imageanchor="1" style="clear: left; display: inline !important; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvi2Pd2QOBb8Bcfd9JXRR4FuRf488wd0ELMu8Ks54xEsK2iLa49suwvkEwhyAbdLDa1ksUMsw8jkFztaJpeGUdo1dVNxrEnmaxQo69fp_67Dza-2iNrcy5JnlLnfV26Btb-bhIuZFtEZce/s400/Finished+009.jpg" width="400" /></a><br />
I'm happy with the results:<br />
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<span id="goog_1389623756"></span><span id="goog_1389623757"></span>Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com2tag:blogger.com,1999:blog-7988465814252285601.post-40509904086571537902010-08-29T22:17:00.000-07:002010-08-29T22:17:08.740-07:00Ewoks Sighted in Northern California<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSFRzYe42l7qUQncMGfProT0bk87RMIJqx0wheZaW_usIapVHDrVsMOvDupURRu0LWhTeM8hLGlcjV4rfUf38STbDaAfbYcEBFs19nE9PxPcA-9qgesvImabQgvsgJOVTr61VRcbCLi5vI/s1600/MattandR2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSFRzYe42l7qUQncMGfProT0bk87RMIJqx0wheZaW_usIapVHDrVsMOvDupURRu0LWhTeM8hLGlcjV4rfUf38STbDaAfbYcEBFs19nE9PxPcA-9qgesvImabQgvsgJOVTr61VRcbCLi5vI/s320/MattandR2.JPG" /></a></div>I almost forgot to mention that while we were having our build day at Chris James' house it appears that there were some Ewoks lurking around the house. But who knew they were so tall? That makes them kinda scary if you ask me.Matt McCormickhttp://www.blogger.com/profile/17071078570021986664noreply@blogger.com0