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

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

It's funny how the main body doesn't look that big from the front with you standing near it, but I know once the legs are under it that thing is going to be MASSIVE
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Looking awesome as usual... Amazing that the cast on the gear came out as clean as it did!

sent from my Galaxy S3 using tapatalk
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Amazing. Did I say that already? Looking forward to seeing the whole beast Sunday 18th -- I may make a beeline for your table first.

And speaking of tables, I love the mini vaccuform rig in your latest video. Shop vac, toaster oven, a "hockey table" constructed from MDF, and just bring together the parts manually, eh? I think I might be able to do that even here at home.
 
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Very, very cool. Well done on such an ambitious project!
 
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So so good keep up the good work, are you buying mold max by the drum?
 
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Massive, massive and massive...those are the only words coming into mind right now:cool
 
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I loved your link, I am going to have to remember that gem.

Ed is coming along nicely as well. I wish that I could go see this guy in person, but sadly 4800 km is a bit too far to drive. I can only hope that the picture do it justice.
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Been watching this build over on Facebook ,had to subscribe to this thread, Be rude not to!

Bloody Awesome!
 
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Stuck to prototype.. what did you seal it with??? Guessing some kind of shellac?

I may not be the best person to ask. You can find all there is to know about this material by clicking HERE.

In other news, I've got the first couple of pulls out of the mold for the inner elbow piece:
https://farm8.staticflickr.com/7240/13908037212_d1668f9400_c.jpg
For some reason, the silicone decided not to let go of the prototype. So I actually had to cut it out in quite a few places. The end result was a lot of chunky weirdness on the finished casting, but I'll be able to salvage it.

Here's the main body as of yesterday:
https://farm8.staticflickr.com/7333/13908027301_8fd718207f_c.jpg

I think it's going to work:
https://farm8.staticflickr.com/7382/13908037432_4a85fe6975_c.jpg

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

Stuck to prototype.. what did you seal it with??? Guessing some kind of shellac?

Nope. It was Rustoleum spray enamel like I almost always use and it had had plenty of time to dry. There was no good reason for the silicone to stick.

UPDATE:
The memory card in my workshop camera decided to commit suicide over the weekend, so I have lost a couple of days worth of photos. Mostly they showed progress on the main body and some work on the dome. Bummer. The best photo I have of the weekend's progress was this shot I took of the back with my cellphone while I was laying under the main body and doing some sanding on the underside:


Otherwise, the only images I have are of the yard where I went shopping for robot parts:




and literally keeping my nose to the grindstone:


Yesterday I was focused on finalizing my other current build, but I had a few friends stop by to help out with ED. By the end of the day we'd managed to get a good start on the mold for the pelvis:


And lay up the third and final part of the mothermold for the second piece of the elbow:


Then get the first successful vacform pull of the armpit parts:


There was more, but those were the best of the photos.

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

I can't believe I was watching the videos on the make blog but never thought to check here for a build thread. Durr.

Sent from my Etch A Sketch.
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

I thought your space marines and dead space suit were impressive. This is quite the undertaking, especially at this pace. I'm enjoying watching it all come together.
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

I think you need a documentary made of all the thing you make. All of your work is just so amazing. And you seem to be pretty efficient at it too!


Sent from my iPhone using Tapatalk
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

I really love this build for sure...that vacu-form piece is worth the price of the admission:cool
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

It's looking great, I can't wait to see it fully assembled! So, what do you do for an encore?... :D
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

Nope. It was Rustoleum spray enamel like I almost always use and it had had plenty of time to dry. There was no good reason for the silicone to stick.

.

It was 100% the rustoleum, whether it didn't dry correctly because of humidity or something else... it was definitely an interaction of chemistry... silicone doesn't have a mind of its own, it reacts with what it comes in contact with much like any other chemical would do.... if there was still solvent residue or soft enamel surface, the silicone could potentially bond, any silicone could potentially bond with that issue. Sorry, I know how frustrating that can be.
Anyway, I have to say this is an AMAZING project.. LOVE LOVE LOVE it!!!!!!! Always can't wait for the pics!
 
Re: Lifesize ED-209 Build. Check it out. You have twenty seconds to comply...

It was 100% the rustoleum, whether it didn't dry correctly because of humidity or something else...

I'd agree with you, but there's more to the story. When I mixed up the rubber to make the print coat for that part, I mixed enough to coat both parts of the elbow. The other piece was made of the same material, and painted with the same paint from the same can at the same time. Both parts had well over 24 hours of cure time and for some reason the other part came out nice and clean. Here's a casting in Onyx as it was being pulled:


I was making a new mold for one of my Combat Garden Gnomes at the same time. The model that I was molding was painted over a year ago and for some reason a couple of patches bonded to the face and I had to scrap the mold. I guess these things happen.

But we're beyond that little problem now and I've just resigned myself to having to do a hell of a lot of cleanup work on one half of each elbow. Here's one of the elbows coming together:


In other news, the mold for the pelvis is halfway done. Here I am laying up the gelcoat on the second of what will be four parts:


Bodyshop work continues on the rest of the main body:




Finally, I've had a friend of mine with a machine shop turn down some aluminum tubing to fake the threaded rods that will run up the inside of the back of the legs:


More progress to come. Stay tuned...
 

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