R2-Start

Last Updated 7/11/99

If you are at this site you are porbably building an R2D2 and also probably belong to the R2D2 builders group. I have built robots for a couple of years and even though they do some real cool stuff, they end up looking like the inside of a TV set on wheels. So I decided to make a better looking exterior, R2D2 was my choice. I am now realizing this is a lot of work (understatement). Since I have just started there is not much to show and so far not one usable part, but they keep getting better. I will be using styrene,aluminium,fiberglass, and some wood. Because of the high torque of the motors the feet will be reinforced fiberglass as will the legs.

Im starting with the feet/legs because the seem to me to be the most complex. At this point I plan to make the body diameter 18" (just because its an even number and it needs to navigate through doorways where size counts). My goal is not really to get it exact to specs (which I dont really have any way) but to make it so close it would need to be measured to discover the error.
My specialty is programming and electronics definetly not mold making so it may be a while before I get the body parts done. However I have most of the electronics done including a vision system. I will trade electronics (motors,micro controller motor controller, remote control from RF or TV remote control, obsticle avoidance, etc.). I make my own circuit boards and have desigend a robot back plane system. Its kind of like a mother board on a PC. Put the droid mother board in the droid and add the plug in boards as needed. I will post some PICs and more detailed explinations of this stuff if any ones interested.

Attempt Number 3 (better but not there.)

No. 3 sitting on the vacum table. Notice the slot did not suck down far enough and a ridge in the side.

Attempt number 2. I twisted it while placeing it over the mold (woops) then I tried to use a heat gun to fix it, thats what melted the top.

This shot shows the 2 12 volt 3.5 amp gearmotors that will move the droid along. These motors are very high torque and max out at about 100 RPM's.

Here are some of the molds during construction, what a mess. The white power pack is a vacume molded piece. In the middle are the foot and powerpack plug (masters) during thier final stages. The black pipe cut in half is what I used for the round power pack forms when I made the plug. It was exactly the right size (for me). The plaster cover black items are silicone molds made from the power pack.

A few people asked about the vacume table. It is a sheet of 1/4" particle board on the bottom. A frame of 1"*2" boards and then a piece of peg board on top. THe frame was caulked to seal the edges. In one end there is a hole where I put the shop vac hose. The shop vac is 4.5 horse power but I found if I remove the filter I get a little more suckage. Also it is important to get the plastic (styrene,abs,pvc) soft enuogh. I wasted several pieces before I got the hang of it.

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