Adam's R2-D2 Droid

Intro

After building two full-size Daleks I've decided to build a full-size R2-D2 droid, the star of the the Star Wars films. I intend my R2 to be fully remote control, something that I will need to learn about as I build him.

I have wanted to have a go at building an R2-D2 ever since I saw the original film way back in 1977, but always felt that I wouldn't be able to. Then I took my Dalek along to a meeting of the UK Robot Builders, and saw three R2-D2 droids, all in various stages of being built. I decided that I was finally going to build one for myself.

Over the past year I have been slowly collecting parts for my build and now with the second Dalek completed I turn my full attention to the little guy...

r2.jpg (24158 bytes)
This is R2-D2 from the films

Month 3 - May 2008
Curved plywood is screwed to a base	Thin strips of MDF get glued to the edge of the plywood	They are then tied up to keep the strips in position while the glue drys	Once the glue has dried they are removed from the base and the ends trimmed
The 'barrel' sections are cut in half and screwed to another backing board	The backing board keeps my hands away from the blade while making a 35 degree cut across the end	The end is sealed off with another piece of MDF, then two are glued each side of the center leg	The outer legs have a slot cut into the flat part, which is then blanked off from behind to leave a recess. These are then glued to the outside of the legs
All the curved ankle parts fixed to their legs. The center one now has a bit of filler to smooth the curve out	Two more pieces of plywood cut on the router.	Top profile	Bottom profile
Glued together they make the large data port that fits at the top of the body at the front	Test fitting in the inner skin	The top of the frame is cut to allow the large data port to fit	The horseshoes get some receses routered in them for the buttons and hydros to fit into.
Outside foot started	To make the curved section lots of thin strips are glued across the gap. The feet will eventually be made in fibreglass	Smoothing the curve with a bit of filler	Half-moon detail added in balsa wood
Smoothed off with filler	Center foot has a half-moon detail on each side	Just need to fill the gap	Getting there
Painted in G4 sealer ready to make the fibreglass moulds	Leg booster covers cut from solid 2x4 timber, planed down to this 'house' shape	Details and the center of the booster covers cut out	'Dog-house' detail added
More resin bits arrive from America. This should be the last lot as I think I can make everything else.
Month 4 - June 2008
Disc of MDF cut to help locate the bearing centrally	Disc held in place with a single bolt at the center, the bearing then fits over it	Bearing is bolted to the top of the frame and the MDF disc removed	Cutting the center of the frame top out using the router
Much better for access	Test assembly of leg parts
Month 5 - July 2008
Plastic used to mask off part of the wooden feet	Middle section covered in fibreglass	End parts removed...	... then the ends get covered in fibreglass too.
Wooden parts removed, I am left with a three part mold that bolts together	Outer foot mold with one end off	Outer foot mold ready for use	The molds get fibreglass resin and matting on the inside
Once set the ends of the mold get unbolted and remove easily	The middle section is more stubbon and requires a bit of pressure to release	Outer foot shell, fresh from the mold	Three feet made.
Three Feet	On his feet for the first time	View from the back	Dome needs a bit of work!
Lower part of the feet is now made in MDF	All the feet have a lower part to them. These are the sections seen from below	Covered in blue G4 sealer to make molds from	Top of the leg booster covers get cut from some MDF offcuts that I've glued together.