Long Time, No See…

Lots has changed since my last post, pretty much all for the better.
We moved to another state (one state back closer to where we were born). Our former house had a problem with gang violence. Our house took a few bullets from a gang shooting. As the police told us, they picked up over 300 spent brass casings off the street, and that was just one side of the shooting. There were also a couple drive-by shootings, and my wife’s car took a bullet from one of those.
The new house is much more in the country. There’s only 12k people in the county that we live in now. I’ve got the equivalent of a 2.5 car garage as my workshop now.

On the droid side of things, I picked up a Com8 (budget) frame, and I’m selling off the (Senna) birch frame I have. I plan to stick with wooden legs. The new frame is together and waiting for me to get some more done with it. I think the next step is getting skin-mounts and then maybe work on mounting legs to it, as well as getting further with the legs.

Hopefully it won’t be another 3 years before I can start making more progress.

Leg Day

Finally took some time to make some headway again with R2. I took the legs partially apart to make sure I knew what was glued up, and what isn’t. The big thing was attaching the extra plates and ankle outer attached. On several occasions the ankle outers and the plate they’re attached to, have fallen off the cabinet they’re stored on top of, and hit me in the head. They’re no longer loose, so that won’t be a problem anymore.

At the same time, I also glued in some of the pins used for alignment. They fit snug enough that they’re an option for keeping the legs together as well. Most of the leg layers are glued together, so they’re really only supporting two parts being held together. At some point I intend to affix those parts together, but I think I want to either put some sort of conduit in the legs, or at least run wires through the legs so I’m not having to fish wire through there later.

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Catching Up

Last year we bought a house not long after my most recent post here.  That’s taken up a huge amount of my time (and spare cash flow), especially as it has a pool.  I had to figure all of that out.  But now my budget has somewhat recovered and with Covid, I have much more time around the house (I work from home now).

The new house didn’t come with the workshop I had hoped for.  I did buy a resin printer though, and I have an FDM printer on the way; should be here in August.  That’ll give me methods for some parts.  They’re both relatively small print beds, so I won’t be printing legs or a dome with them.  I did replace some of the tools that I sold when we moved out of Rochester, so I can try to get back to some building hopefully soon.

I’m also trying to find some local builders that I can get advice from.  I have a few decisions to make, and I’m at a point where those decisions will have impact on later parts of the build, so having some experience to work from would be great.

Non-Progress Progress

While I haven’t made any progress now in months, I’ve made related progress.

First, Artoo got an “official” space in our apartment.  He’s got his own shelf in our spare bedroom.  This means I’m not catching grief from the wife unit about having Artoo parts spread across the living room.  It’s a big shelf with enough clearance above it that Artoo’s body sits on top with his skins taped around him, and his legs sitting on the shelf beside him.  He’s also high enough up that if the kids come to visit, he’s basically out of reach.

Second, we’ve been house shopping.  Each of the houses we’ve put a bid on (or tried to put a bid on, in one case) had phenomenal workshop space.  The first one (Lindley) had a 900 sqft detached workshop, but it turned out there was water damage and there was likely to be more water damage to the house in the future; it was built next to a hill that would drain against the side of the house, and North Carolina has lots of clay in the soil, so water doesn’t soak into the soil very quickly.  We were really interested in a second place (Brenrose), that had 2 garages and a carport; with one of the garages even having a hydraulic car lift in one of the bays.  It sold before our realtor could get us an appointment in to look at the place.  The third place (Marly) had a nice detached garage.  The garage wasn’t as large as place #1, but it was big, was open to the rafters, which could have added storage and usable space in some odd ways, but didn’t have power run to it.  We loved the house and the location, but when we started looking deeper, we realized the place needed about $15k in repairs, but was still listed at $240k.  Then there was the fourth place, Holder.  It was really nice inside, in many ways too nice.  My workshop would have been inside, with white carpet.  The master bedroom was small, and the seller wasn’t willing to budge at all on the price, and absolutely against offering any closing cost assistance.  Cori fell in love with it, and was crushed when we walked away.  I’m not sure why she loved it so much; to me it almost seemed too formal for us.  The location wasn’t awesome, but it certainly had a country feel to it that I liked, but I didn’t love it.  The fifth place (Wayne) had an awesome workshop in the basement, along with storage areas down there, and a bathroom.  It also had a small (approximately one car) detached workshop and a shed.  I think we would have removed the shed sooner or later because between the workshop and the out building, there was plenty of storage and workshop area, and the shed was sitting where we’d put a pool in.  It turned into a bit of a bidding war, as we lost right away.  So we’re still looking.  It’s safe to say that the housing market in Durham is a little crazy.

Third, Ian upgraded his 3d printer so it’s has dual extruders.  This means he can use water soluble plastic for supports and finishing becomes a bit easier.  This is really cool.  At some point, I’ll have to get some pics of some of the stuff he’s printing now.  I keep wanting to pick up a 3d printer, but the amount of work he had to put into this makes me glad he’s doing it, and not me; I don’t have the time for a whole extra hobby, and don’t have the space for a 3d printer right now either.  Part of me is tempted to pick up an SLA printer to compliment his FDM printer, but there’s less use for an SLA printer, other than printing minis, as SLA prints tend to be pretty brittle.  SLA printers also have a high cost when it comes to consumables, as there’s significant parts (resin basin and print bed, ~$150) that are considered “consumable”.  So it’s on the “want list”, but it’s very far down in priority, especially while we’re still in an apartment.

I haven’t given up

Artoo is currently packed away in our spare room.  This summer proved to be busier than I had expected (thank goodness in many ways).  It also proved to me that summers in North Carolina aren’t particularly agreeable to painting; either the weather was too hot, too humid, or both; at least when I had time to paint.

I did get a coat of primer on a few parts early in the summer, but the primer just about rubbed off.  I learned I need a coarser surface to work with so the primer and paint aren’t so likely to peel or scratch.

Company meant that my darling wife didn’t want Artoo taking half the living room, and the small apartment we’re in didn’t have a good place for him, so he ended up nicely packed in a corner of the spare room where he was more out of the way.  For the company that spent the night in that room, it drew some questions of curiosity, but it didn’t get damaged, which was one of my concerns.

In the spring, we intend to buy a house.  The house will have a workshop, so I will have space to put together armour and droids.  I’ll continue to get parts here and there as budget allows (not building over the summer allowed me to get my debt down, so budget will be less of a concern in the future).

More Printed Parts

Ian is keeping me in parts, in fact to the point, where I’ve got a significant build up of spares.  I’ve got like 3 sets of booster covers.  Granted they all have defects, but to someone who doesn’t mind doing some finishing work, they’d be fine.  He made me an extra (better) set of shoulder hydraulics, and printed me a set of shoulder buttons, and a test run of the under shoulder details.  This does mean my legs will get done first and then I can start working on the body.

Weather is still keeping me from doing any real finishing work, but it seems like it might cool off next month, so I can start doing some real work again.  I’ve set up a pseudo-workshop out on our porch with a make-do paint booth and a small work bench.  This means I won’t have to keep cleaning up messes in the middle of the living room.

3D Printed Parts – So Far…

To show off what I have so far, I took a picture.

The shoulder hydraulics are PETG.  They were printed differently.  One was an early draft, printed with a .5mm nozzle.  The other was like a 3rd draft, printed with a raft, and a .2mm nozzle.  The one with the better knurled area is the one printed with the finer nozzle.

The shoulder hub is a first draft.  Ian had printed me the “standard” 3 piece model from the Astromech.net 3d file vault.  Ian wasn’t satisfied with quality of the model.  It had lots of flat spots on it and wasn’t a tight fit.  He remodeled into a single piece, made of more efficient parts instead of having the “low polygon” look of the original.  The remake was made from circles and cones.  It was printed with PLA instead of PETG as we realize these will be “protected” and don’t need to be super durable.  2018-07-15 08.18.47

External Link Page Request

I got a request from another web group that asked if I would be willing to add them to my “external links” page.  Right now, they’re not pertinent to what I’m doing.  Once I get further along, and get to the parts where I’m installing electronics and programming Artoo, they might become more relevant to the project.  If I use the site some, I might add them to the external links.  For now, they’ll get a mention within a post, here.

Maker Pro is an active, open source platform for maker projects much like Hack A Day.  These projects are centered around Arduino, Raspberry Pi, Intel Edison, home automation and more.  The content is completely user generated.

If someone were looking for a link-trade and is doing something quite relevant to what I’m doing here, I’m open to discussion of adding sites to my external links.  Right now, the sites listed there have been instrumental in helping me get my R2 project going, so they’re listed without any hope that they’ll link back to me.

Hold Ups

Weather in Durham, NC is hot and humid.  I’m at a point where I really want to get some parts finished (in automotive terms, as well as common meaning), but the heat and humidity are putting a cramp in my plans.  When I shoot parts with primer, it doesn’t want to seem to dry for an hour.  If I bring them inside so they dry “normally”, the whole apartment starts to stink of spray paint.  So I’ve been stopped on putting parts together.

The positive side is that Ian keeps printing parts for me.  He printed me a 3-piece-shoulder-hub, that I was pretty happy with.  He improved the model and printed again as a single-piece, which looks great, but will be harder to finish because it’ll be harder to get sandpaper inside the nooks and angles.  He’s considering going back to a 3-piece model for his next draft.  It’ll be better than the original model I got from the astromech builders club, as it’ll be “higher polygon count”, so less flat spots, and will print as concentric rings instead of zig-zag, which should help in overall finish.

Ian also printed me the shoulder hydraulics.  He went through a couple iterations with them, and learned a few things about nozzle size and resolution with the exercise, which I expect to help with future part prints.  We’ve also gone back to PLA, as the parts we’re printing now aren’t structural, and will get painted, so I’m less worried about weather taking a toll on them.

Ian’s adventures in 3d printing is really tempting me to pick up a 3d printer, but at the least, it’ll have to wait till we get a house as the apartment really is too small to have a 3d printer in the mix as well.  I can’t wait to have a workshop again (with AC and a dehumidifier, and maybe even a small spray booth).

Booster Cover Finishing

I got started on finishing the booster covers.  I sanded the big surfaces on both pretty well, with 220 grit and a sanding block.  They sand up pretty nicely.  Then I built myself a spray booth out of cardboard, so I wouldn’t get over spray all over the apartment porch; there’s not much space out there, and everything is white vinyl, so over spray would show up quite a bit.

The first coat of primer looked a bit thick to me, so I wanted to sand it down some to make sure it wouldn’t look bad in the end.  Better to sand the cheaper primer than the pricey paint.  And the primer started coming off very easy.  The spots that got good sanding had pretty good adhesion, but anything that was a low spot, or didn’t get sanded because it wasn’t a big surface, primer peeled right off.  Probably didn’t help that it was 90+ degrees outside, and probably 90% humidity.  So I sanded one of them completely bare, making sure to sand every surface as much as possible to keep the primer sticking better next time around.