Re: 1:1 Wall-E Build (WIP) - Gear Assembly Complete!
Oh Man... That is a thing of beauty! Dang... your workbench is clean...
Oh Man... That is a thing of beauty! Dang... your workbench is clean...
1:1 Wall-E Build - 2014 Halloween Appearance
- Thread starter Snow Builder
- Start date
Re: 1:1 Wall-E Build (WIP) - Gear Assembly Complete!
A little something extra I built into the table -a vacuum access.
Great for sucking in sawdust, paint dust and overspray, and using as a small trash can.
I have some PVC and couplers running underneath the table to an easy hookup to the shop-vac
I keep a stiff bristle brush near by so I can wipe the table right into the vacuum port.
One of the most rewarding projects I've ever done
Thanks!
A little something extra I built into the table -a vacuum access.
Great for sucking in sawdust, paint dust and overspray, and using as a small trash can.
I have some PVC and couplers running underneath the table to an easy hookup to the shop-vac
I keep a stiff bristle brush near by so I can wipe the table right into the vacuum port.
One of the most rewarding projects I've ever done
Re: 1:1 Wall-E Build (WIP) - Gear Assembly Complete!
So, where to start…?
Wall-E has been more of adventure than I was looking for over the last several days. The next task was to figure out how to attach the gear assemblies to Wall-E. Of primary consideration is 1) he's heavy, 2) he's fragile, and 3) I don't trust the sides to be able to bear his weight.
Solution? Join the two gear support frames and build a "platform" on which he can rest.
The wood blocks on top are, in part, ornamental but their primary purpose is two serve as guides for attaching the body. Here's everything all painted and weathered.
My goal was to not only have the gear assemblies completed and attached by Halloween, but to have the treads done as well. First I cut a couple of pieces and attached them with dowel "pins"
Seemed like a feasible approach, let's make more…
Short version, this isn't going to work. The links don't have enough room to pivot on their pins properly and it's causing the wood to snap. I figured out an alternate approach that I'm trying, but there won't be any treads in time for the trick-or-treaters (not to mention, my band saw went belly-up at the last minute)
…and, once I fully assembled Wall-E with his new "legs" he was front heavy, snapped a couple of wooden retaining rings and fell on his face. Sigh.
Fortunately the damage was minimal, but my lack of engineering skills is definitely showing. My solution is to build him a couple of skids that will better bear and distribute his weight. Skids are attached with both wood glue and 2" screws.
Painted and weathered
I also revisited the tension supports. I wanted to add more of a metallic look with more greasy fluids.
and here he is all assembled
He got a lot of compliments from the trick-or-treaters (and their parents) and we had a great time.
More to come...
Thanks!Wow!
The gear looks so real and high-quality, great!
Btw, genius solution with the workbench and the vacuum!
So, where to start…?
Wall-E has been more of adventure than I was looking for over the last several days. The next task was to figure out how to attach the gear assemblies to Wall-E. Of primary consideration is 1) he's heavy, 2) he's fragile, and 3) I don't trust the sides to be able to bear his weight.
Solution? Join the two gear support frames and build a "platform" on which he can rest.
The wood blocks on top are, in part, ornamental but their primary purpose is two serve as guides for attaching the body. Here's everything all painted and weathered.
My goal was to not only have the gear assemblies completed and attached by Halloween, but to have the treads done as well. First I cut a couple of pieces and attached them with dowel "pins"
Seemed like a feasible approach, let's make more…
Short version, this isn't going to work. The links don't have enough room to pivot on their pins properly and it's causing the wood to snap. I figured out an alternate approach that I'm trying, but there won't be any treads in time for the trick-or-treaters (not to mention, my band saw went belly-up at the last minute
)…and, once I fully assembled Wall-E with his new "legs" he was front heavy, snapped a couple of wooden retaining rings and fell on his face. Sigh.
Fortunately the damage was minimal, but my lack of engineering skills is definitely showing. My solution is to build him a couple of skids that will better bear and distribute his weight. Skids are attached with both wood glue and 2" screws.
Painted and weathered
I also revisited the tension supports. I wanted to add more of a metallic look with more greasy fluids.
and here he is all assembled
He got a lot of compliments from the trick-or-treaters (and their parents) and we had a great time.
More to come...
Last edited:
Archive&Future
Sr Member
Re: 1:1 Wall-E Build (WIP) - Halloween Debut.
Wow! He's huge cor
Wow! He's huge cor
Re: 1:1 Wall-E Build (WIP) - Halloween Debut.
I had to disassemble him to bring him back inside. I've got some repairs and upgrades to do before I put him back together, but I'll get you measurements shortly. At about 3' I'd say your pretty darn close to scale.
Yeah, it's amazing how big he is. If you re-watch the movie you actually see he is pretty big relative the people, but he does create the impression of being much smaller.
I had to disassemble him to bring him back inside. I've got some repairs and upgrades to do before I put him back together, but I'll get you measurements shortly. At about 3' I'd say your pretty darn close to scale.
Re: 1:1 Wall-E Build (WIP) - Halloween Debut.
The treads extend outside the gears, so I don't have a measurement for his width (yet).
Cutting the tread pieces (this is tedious)
A short segment of tread all linked together
Determining how much more tread I need
One tread done! (this represents about 3 hours of work)
More to come...
I'm sure you have the same experience with your R2 -hard to wrap your brain around how big he is until you actually are next to one.I have also always though of Wall-E as a smaller robot than this, but now I realize how big he actually is!
About how wide is Wall-E, including the gears? And, great work once again!
The treads extend outside the gears, so I don't have a measurement for his width (yet).
Cutting the tread pieces (this is tedious)
A short segment of tread all linked together
Determining how much more tread I need
One tread done! (this represents about 3 hours of work)
More to come...
Re: 1:1 Wall-E Build (WIP) - Halloween Debut.
Hey SB,
I've been out of pocket for a while... MAN-O-MAN! Wall-E looks AWESOME! The treadwork is fantastic! We'll definately need to get a pic of him with R2 in front of the Pit - they are all related now.
Looking forward to more!
Hey SB,
I've been out of pocket for a while... MAN-O-MAN! Wall-E looks AWESOME! The treadwork is fantastic! We'll definately need to get a pic of him with R2 in front of the Pit - they are all related now.
Looking forward to more!
Re: 1:1 Wall-E Build (WIP) - Halloween Debut.
Thanks! (you sure know how to make a prop builder feel good -I appreciate your enthusiasm for my little project). It'd be a blast to get a picture with Wall-E, R2 and the pit -if you make any conventions out in the Kansas City area we'll definitely make it happen.
I travel a lot for work, so it's not beyond the realm of possibility I'll come knocking on your door one day to get a personal tour...
I had a pretty crappy Ryobi band saw that gave up the ghost on Halloween morning (course, I got three years out of it, so I shouldn't complain too loudly).
It took three attempts to get a decent Craftsman saw -the first purchase was defective (the drive belt kept slipping off), the second was a floor model that was missing a critical part, and now we're on the third). So far I'm pleased with it, but I haven't shopped blades yet -looks like you've given me something to worry about
Started working on the second tread this afternoon, hopefully I'll have more pics to post shortly.
More to come...
Hey SB,
I've been out of pocket for a while... MAN-O-MAN! Wall-E looks AWESOME! The treadwork is fantastic! We'll definately need to get a pic of him with R2 in front of the Pit - they are all related now.
Looking forward to more!
Thanks! (you sure know how to make a prop builder feel good -I appreciate your enthusiasm for my little project). It'd be a blast to get a picture with Wall-E, R2 and the pit -if you make any conventions out in the Kansas City area we'll definitely make it happen.
I travel a lot for work, so it's not beyond the realm of possibility I'll come knocking on your door one day to get a personal tour...
I had a pretty crappy Ryobi band saw that gave up the ghost on Halloween morning (course, I got three years out of it, so I shouldn't complain too loudly).
It took three attempts to get a decent Craftsman saw -the first purchase was defective (the drive belt kept slipping off), the second was a floor model that was missing a critical part, and now we're on the third). So far I'm pleased with it, but I haven't shopped blades yet -looks like you've given me something to worry about
Started working on the second tread this afternoon, hopefully I'll have more pics to post shortly.
More to come...
Re: 1:1 Wall-E Build (WIP) - One Tread Complete
Yay! Second tread finished and priming and painting underway.
For those interested in minutia, I thought I'd show how the sausage gets made…
Created an MDF template for marking out the tread plates
A full tread takes a LOT of plates
Once I use my band saw to cut the pieces, I use a couple of MDF spacers to align a plate and drill a pilot hole on each side
Keeping the spacers in place, drive a nail (pin) into each hole
One of the finished treads. It's slightly over 5 feet long
Sanded and primed
…and painted and weathered (one side)
Need to paint the other side then start on sanding/priming the other tread.
More to come...
Yay! Second tread finished and priming and painting underway.
For those interested in minutia, I thought I'd show how the sausage gets made…
Created an MDF template for marking out the tread plates
A full tread takes a LOT of plates
Once I use my band saw to cut the pieces, I use a couple of MDF spacers to align a plate and drill a pilot hole on each side
Keeping the spacers in place, drive a nail (pin) into each hole
One of the finished treads. It's slightly over 5 feet long
Sanded and primed
…and painted and weathered (one side)
Need to paint the other side then start on sanding/priming the other tread.
More to come...
Kevlarr
Active Member
Re: 1:1 Wall-E Build (WIP) - The Tread Adventure Continues...
I saw another guy who made a functional Wall-E and he casted the tracks from some kind of rubber in a mold who took 6 pieces at the time. Not sure if it was rubber, but it was some sort of soft plastic.
If the tracks are made of metal it takes quite a machine to make it move and it would probably weigh at least 50 pounds more + metal tracks are hugly expensive.
Snow builder:
You're doing great, and that's a whole lot of tracks. Looks like you have given quite an effort to get it done, and it seems like it was worth it. Looks awesome!
How do you keep track on them?
Alright, a silly pun...
I saw another guy who made a functional Wall-E and he casted the tracks from some kind of rubber in a mold who took 6 pieces at the time. Not sure if it was rubber, but it was some sort of soft plastic.
If the tracks are made of metal it takes quite a machine to make it move and it would probably weigh at least 50 pounds more
+ metal tracks are hugly expensive.Snow builder:
You're doing great, and that's a whole lot of tracks. Looks like you have given quite an effort to get it done, and it seems like it was worth it. Looks awesome!
How do you keep track on them?
Alright, a silly pun...
Re: 1:1 Wall-E Build (WIP) - The Tread Adventure Continues...
I have some experience casting and molding, so I could have created a gang mold similar to what was done in the video, but that would have significantly ramped up the cost of the project. By going with wood I think the total cost of the treads (excluding the cost of the new band saw) was about $20. Course, I paid for the treads with my time, rather than with cash...
The weather just turned very cool over the last couple of days, so paint is taking a LOT longer to dry. I'm hoping to get the treads clear-coated and on Wall-E within the next couple of days.
More to come...
Thanks for the compliment. Since I built Wall-E with the intention of keeping him static, I haven't done any research on what would be required to have mobile treads. Anyone know what snow mobile treads are made from?
Thanks!
Thanks for the assist. Here's the video you're referring to specific to a mobile (and incredibly cool) Wall-E.I saw another guy who made a functional Wall-E and he casted the tracks from some kind of rubber in a mold who took 6 pieces at the time. Not sure if it was rubber, but it was some sort of soft plastic.
If the tracks are made of metal it takes quite a machine to make it move and it would probably weigh at least 50 pounds more
Snow builder:
You're doing great, and that's a whole lot of tracks. Looks like you have given quite an effort to get it done, and it seems like it was worth it. Looks awesome!
How do you keep track on them?
Alright, a silly pun...
I have some experience casting and molding, so I could have created a gang mold similar to what was done in the video, but that would have significantly ramped up the cost of the project. By going with wood I think the total cost of the treads (excluding the cost of the new band saw
) was about $20. Course, I paid for the treads with my time, rather than with cash...The weather just turned very cool over the last couple of days, so paint is taking a LOT longer to dry. I'm hoping to get the treads clear-coated and on Wall-E within the next couple of days.
More to come...
Last edited by a moderator:
Re: 1:1 Wall-E Build (WIP) - The Tread Adventure Continues...
How are getting those 90 degree cuts on the inside with a bandsaw? Are you cutting the inside corners round first then going back and squaring off once the main chunk of material is gone?
How are getting those 90 degree cuts on the inside with a bandsaw? Are you cutting the inside corners round first then going back and squaring off once the main chunk of material is gone?
Re: 1:1 Wall-E Build (WIP) - The Tread Adventure Continues...
Exactly right (wish there was an easier way to do it).
Exactly right (wish there was an easier way to do it).
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