Lifesize ED-209 Build. NOW WITH EVEN MORE ED on p.23!!!

thorssoli · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Snow Builder said:
I see you using the action figure as a reference, but how are you scaling your plans? To what level are you creating blueprints and virtual parts prior to each piece being built?

I'm not really creating blueprints at all. For the most part, I pull out a piece of sheet stock, take measurements off of the figure, multiply them by my scale factor, and draw them straight onto the material to be cut. I've been using a scale factor of 10.6 for most of the parts. The main exceptions being the pelvis, toes, and gun pods. I've made the pelvis and toes narrower from side to side, but otherwise kept the proportions of the action figure.

I decided that the gun pods weren't correctly proportioned in the action figure, so I'm using a scale factor of 11.7. The barrels are comically long on the action figure as well, so when I get to that part, I'll end up shortening them significantly.

Whenever I run into a part that seems wrong on the action figure, I spend a lot of time looking back over the behind-the-scenes images to figure out how the original prop looked. The action figure is pretty good, but there's a few issues that were caused by cutting corners in order to make it easier to manufacture.

renderinfo · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

This build is "amazing", "astounding", "incredible", etc...

The devil will be in the final details.
In my opinion, the final painting and detail work required to make this "movie-authentic" will be painful and time consuming on a model of this scale. If you wanted, you could easily spend as much time (and maybe money) detailing ED as you are doing finishing all the parts and putting him together. I'm thinking things like color, texture, mesh, chrome, steel, small details etc will be massive, just like the model itself. If final detailing is done right, you will have a MASTERPIECE, but if done "wrong", all your time, money and superior effort could be "wasted" (relatively speaking). Do you have any in-sight you can share on how much and and what kind of detailing you are planning to do once all the pieces are done and put together?

thorssoli · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

renderinfo said:
Do you have any in-sight you can share on how much and and what kind of detailing you are planning to do once all the pieces are done and put together?

All of the detailing. I have no doubt that this build will be finished at least as well as any of my other projects. If you're worried about it, you can see many examples by clicking HERE.

If anything, this build is made much easier by virtue of the fact that I won't have to design it to fit around a performer. That means I can devote even more attention to putting in the little details. The large scale will just mean a shift to larger scale tools. Instead of the airbrush, I'll be using an automotive HVLP gun to spray the base colors. Instead of the Dremel, I'll use a flapwheel grinder to clean up seams. The devil will be in the details, but they're also my favorite part.

renderinfo · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Awesome work! Thanks for the link!
Is that you in the Kali costume and make up?

CVWcreations · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

If it was easier to post I would imagine a ton of users would want one of these in a heartbeat, you might have to do it like a part work magazine 'ed 209 leg and magazine binder with issue one' 'ed 209 to with issue 2' lol.

thorssoli · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

renderinfo said:
Is that you in the Kali costume and make up?

No, try as I might, I just didn't have the legs for it. The girl in the costume is Sarah, my go-to fitness model whenever I need someone on the shorter side with a lean figure to pose in a costume.

IceTea1983 · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Pardon my Harry Potter reference, but what would not most people here give to be a metamorphagus? It would save a lot of measuring effort for costumes, and might not require so much mind bleach from the odd costumer who overestimated their appearances ... sorry, just a thought which struck me and you folks happened to be the closest outlet.

"We now return you to your regularly scheduled topic; ED-209, the full scale prop with a deadline!"

Edit: PS; DO NOT GOOGLE 'COSPLAY FAIL'! THERE IS NOT ENOUGH MIND BLEACH IN THE WORLD TO BURN AWAY THE IMAGES!

ecl · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Holy guacamole, this is awesome.

Prefect42 · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Thorssoli,

Brilliant work here. The videos are extremely helpful to me. I've helped with silicon molds over the years but never felt confident enough to try my own. Along with the details, you showcase the fun of making molds. After watching this latest video, I want to go buy some fiberglass and try my hand at it. Someone gave me a mold for a helmet from a tv show. Now I feel like I can give it a try.

Two questions I do have for you: Will you be using some type of internal armature to support ED or will you just assemble it like a giant kit and let it stand on its own two feet? And what will you do with it when the show is finished? Make it a bird feeder in the yard? Auction it off? Ice chest for beers in the summer? You could hinge the head.

As to less response than you'd expected, I wonder if the shift to designing on the computer and 3D printing is having an effect here.

Ted.

Emmet · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Sure. Those evil computers and Satan's 3D printers. It is all their fault.

Come on, this thread has almost 9,500 views until today - what else can you expect?

I am happy that all those people don't clutter this amazing documentation with posts like "wow" "awesome" "excellent". (Like I just did...)

thorssoli is doing one of the most impressing builds here at therpf.com and I guess most of us are just watching the progress in awe.

nick daring · Mar 31, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

I'm adoring this build but there's not a whole lot to say or ask. Your videos and pictures are so thorough that all questions that I have about the build are quickly and expertly answered!

Great build.

Alric · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Silly question, but I guess you have a big truck to move him once made or will you need to make him to be taken apart for moving ?

gerryc00 · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

man this build is awesome well done so far fellas

thorssoli · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Alric said:
Silly question, but I guess you have a big truck to move him once made or will you need to make him to be taken apart for moving ?

Both. For the last couple of years I've rented a truck to bring my display to the Maker Faire. It's a lot of stuff. Here's my setup from last year:

I usually have about a dozen folks come along to suit up in my costumes and walk around at the event while I stay in the booth and answer people's questions about prop making:

This year will be my fourth consecutive appearance and my footprint keeps getting bigger.

ED will be able to break down for transport, so I could probably fit all of the parts into a standard pickup truck, but I'll still end up with a big moving truck anyway.

The Ronin · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

nick daring said:
I'm adoring this build but there's not a whole lot to say or ask. Your videos and pictures are so thorough that all questions that I have about the build are quickly and expertly answered!

Great build.

What this guy said. I've honestly been inspired by a lot of your builds to try new and different techniques for my own stuff. Thank you for sharing your experience with us.

Alric · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

With the size of your display have you thought of taking it further afield ? I'm sure it would go down a storm at something like comic con.

madscience · Apr 1, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Holy $&*@! Thats gonna be epic!

IceTea1983 · Apr 2, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Just for fun, build one in 1/2 scale, paint it pink and put a bow on its head and fasten a tutu around its hip joints: Daughter of ED; EDWINA-209 = instant cute death; "Giggle, you are -like- so tresspassing. Leave the premises or be -like- fired upon. You have -like- twenty seconds to comply!"

Once again, a random thought which struck me and once again you people were unfortunate enough to be the first available outlet. Sorry.

Edit: TV, Games and the Internet has rotted my brain. Now everything drips out.

thorssoli · Apr 2, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Alric said:
With the size of your display have you thought of taking it further afield ?

It's tempting, but the logistics involved in moving all of this stuff just a couple of hours down the road is already enough of a nightmare. One of these days I'll make it to one of the bigger comic conventions as well, but not until I can find a better way to pay for it.

IceTea1983 said:
Just for fun, build one in 1/2 scale, paint it pink and put a bow on its head and fasten a tutu around its hip joints.

Funny. I've been piling up all of the pink prototype parts when the molds are done and I haven't exactly decided what I'll be doing with them once the project is done. If nothing else, it'd be funny to mock up the whole robot 1/1 scale in pink. Then I can use it for target practice, or light it on fire, or detonate it...

UPDATE:

Started the shoulder flap:

The hinge parts were all cut out by Lopez the Robot Whittler (my CNC machine):

I also had him cut out some circles:

These were tuned up a bit and became the end caps for the hydraulic rams on the upper legs:

They'll look better once they're polished up, molded, and cast.

On the subject of CNC pieces, I had Lopez carve out this piece:

Which was vacformed and installed in the cutout on the side of the gun pod:

And looks a lot better with the vacformed ammo box placed over it:

Busy day lined up for today. Stay tuned...

WarPig · Apr 2, 2014

Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

thorssoli said:
Funny. I've been piling up all of the pink prototype parts when the molds are done and I haven't exactly decided what I'll be doing with them once the project is done. If nothing else, it'd be funny to mock up the whole robot 1/1 scale in pink. Then I can use it for target practice, or light it on fire, or detonate it...

Or SEND IT TO ME

Lifesize ED-209 Build. NOW WITH EVEN MORE ED on p.23!!!

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