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

[thorssoli]

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

I love the videos. Your write ups are excellent and always fun to read, but I am a visual learner and I find that the videos are very useful. I've watched all of them so far and liked and favourited each one. Hope that helps convince them to keep making them!

Thanks. Everything helps.

How's the heat been treating you? The Bay area has been having a mother of a heat wave this week!
Nothing quite like grinding fiberglass when you're sweating like mad!

It has been pretty toasty. The worst part is that there is no climate control in the workshop, so it's usually about ten degrees on the uncomfortable side of the outside temperature.

I LOVE the videos Shawn! Posted the link on my prop page on facebook https://www.facebook.com/NickatronProps?ref=ts&fref=ts

Awesome. More exposure is better.

Yesterday was a slower day than I'd have liked. I started off with Kate helping polish the molds for the pelvis:


After applying mold release, we ladled on the gelcoat:


While we waited for that to cure, we put the first coat of wax on the main body:


Once the wax dried, it was time to buff it:


The whole thing got three coats of wax before Kate had to take off for her day job. That's about the same time that Shawnon and my friend Matt showed up and gave me a hand laying up the glass for the pelvis:


Here's Matt laying up one of the seams for the pelvis:


Once we'd bolted the whole thing together, I laid up the last of the seams:


At some point, the contents of my chest pocket fell into the sticky wet fiberglass:

Because I'm a genius.

While I was doing that, Matt got started on the forming bucks for the toe knuckle joints:


But when I wasn't paying attention to him, he started screwing around with the camera:


Fun:


In other news, the latest article I wrote for MAKE is now live: Building Up to Maker Faire, Shawn Thorsson Brings ED-209 to Life: Part 5 ? Rotocasting | MAKE Be sure to check it out.

12 days to go. Stay tuned...

 

[monolith21]

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

This is amazing.

 

[MTB]

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

This is fantastic! I got my time off approved at work and bought my tickets! I will see you there Sir!

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[MartinSivertsen]

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

I actually came by your build on the MAKE-site in march (although I've been registered over here for a few years), and have been following it dilligently since, I check in on this thread almost daily now.
Being born in the early eighties I grew up watching Robocop and other effects-laden movies myself, and ED-209 has always been a personal favorite as well, showing up in lots of drawings I did and leaving a huge impression on me.
So this build tickles my nostalgiabone in a major way.

If possible, keep up with the updates on the MAKE-site (personally I don't understand how you have the time with the short deadline), and I wish you all the best in getting this finished in time.
I salute you! Go go go!

 

[Snow Builder]

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

I've run out of words, literally.

 

[Jedi GERRY]

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

wow-- just what everyone needs -- their own personal bodyguard ! too cool for words-- amazing...

 

[Fernando]

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

Absolutely amazing. And that videos are great ! Thanks for sharing your techniques !

 

[knightdriver2001]

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

Wow, 3 days and no update?

Going through withdrawls here!

 

[thorssoli]

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

Alright, it's been a couple or three days, so I'm way overdue for an update.

First off, I set up the first round of parting walls on the mold for the main body:




The Lady Shawnon helped me with the gelcoat:




While all of that was going on, a buddy of mine popped the pelvis out of the mold:




My friend Matt got a good start on the forming bucks for what we're calling the "toe knuckles:"


Here those are shaping up:


Here's more of the crew glassing up the main body:




That's always a good time:


Meanwhile, I started cutting holes for the screw head inserts:


Then glued them in:


Once the glue had set, I handed them off to one of the other guys to sand down the seams and whatnot:


So here's most of a leg:


You'll notice that there are no hydraulic cylinders on the thigh. I've been trying to find a tube with the exact right diameter (3" is too small, 4" is too big, 3.5" is ridiculously expensive custom bullsh*t) when my friend Matt came up with a plan:


Since the inside diameter of a 4" ABS drain pipe is about the right size, we cut some rings off of the end of the pipe, rolled some sheet ABS to fit inside, and glued it in place:


Once I add some 2" pipe to fake the rams, they'll be all done. I have all I could ever want:


We've also decided that the whole thing needs a frame to sit on. While I can weld, my seams usually end up looking like they're made of moon rocks. Instead, I shanghaied my father into doing a bit of steel work. Here he is when he stopped by to discuss the design of the frame:


Here I'm explaining to him what the leg will look like:


This morning I stopped by his workshop and snapped a picture of the foot pads in progress:


And the uprights that will slot together to fit inside the legs:


Still, the long pole in the tent at this point is the mold for the main body. Here's what it looks like right now:


It should be finished in two days. Then I'll be getting the whole crew together to clean, polish, gelcoat, and glass it so we can pull a copy as quickly as possible.

I've got 8 days left before the whole thing has to be on a truck. Then I can relax a bit.


8 days. Stay tuned...

 

[Snow Builder]

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

sitting on edge of seat...

This is a terrific build, it will be great when you're actually able to sit back and enjoy the finished result.

 

[The Ronin]

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

I'm getting nervous FOR you. I know you can do it, though.

 

[Sean]

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

Awesomeness ! all the best for the eight day's. and that last pic Is a hoot...lol

 

[jim fred]

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

Only eight days ! What will we all do when updates stop ! I mean it's okay to check this thread every hour right ?


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[clonesix]

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Using the ABS as a mold? Your friend is genius.

 

[joberg]

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

Wow, 8 days...I cannot take the suspense and I'm not even building the thing and keep that friend of yours: ABS as the mold for the pistons: RAD!!

 

[panterateama]

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

This is gonna be great! And there is no way this is over... Knowing you, the minute this is done, you'll have something else crazy to work on.

Check out my profile for my Assassin's Creed projects and my Star Wars communicator!

 

[Mrdopey]

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

This is amazing! If my wife would let I would put one in my yard... now that's a deterent

 

[nick daring]

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

Tight deadline. I love the suspense!

 

[Crimson13]

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

It's the final stretch!! Your updates are one of my highlights of my long work days. Keep up the awesome work!


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[thorssoli]

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

foot assembly. Started 8:30am:


Flipping the main body:
[

Cleaning off edges:


Building mold walls:


Prepped:


Glassing:


Butt box around midnight:


Gotta work dome:


Bondo Dome:


Fairing:


Meanwhile in the metal shop:


Framed:


Big robot legs are big:


Words no blah sentences hard write I feel like this now:


7 days. Stay tuned...