Lifesize ED-209 Project - UK

I was asked on the facebook page by someone if they could buy the masters and I said no, mostly because I didnt think they would survive the demoulding process, and they didnt

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Started moulding the gun pod and found I had run out of gelcoat :-( I had a delivery the other day so I should be able to carry on with this

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Built the elbow flap last night, still need to do some filling and shaping, then paint it and mould it

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Some of the 3D models I designed to be put on my CNC machine, some of them didnt work or I haven't machined them yet. some parts I need to redesign like the connectors for the gun pod I have decided to simplify and the gimble which attaches the elbows to the body

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so this is a cog that would be part of the elbow for the gun pods, I am going to redesign this as I have decided not to do it the way I originally thought I would so this part is no good for the new design.

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so where I am at at the moment, I have built 95% of the masters, outstanding is the elbow cog and cups to connect to the gimble and gun pods, a few vents for the body, an insert for the gun pod so the ammoboxes can it on it, otherwise I now have everything, I just need to finish moulding it all.
 
Phenomenal work, sir! The world needs more ED-209s.

It looks like you'r using the NECA action figure for a model. May I ask what scale factor you're using to make it full-sized?
 
Phenomenal work, sir! The world needs more ED-209s.

It looks like you'r using the NECA action figure for a model. May I ask what scale factor you're using to make it full-sized?

Hi, thanks for the compliment, I have you to thank for the inspiration ;-) this should be the only one outside the US

Yes using the NECA same as you did, and the same multiplier 10.6 with a bit of rounding, and I am using metric measurements so there will be some slight differences between mine and yours.

Mine is taking considerably long than yours took as I am doing near enough all of it on my own.

I'm going to be in San Francisco at the end of the month beginning of March was thinking of shooting you a message to come and visit EDs older brothers/ US cousins ;-) and see your workshop and stuff. I'm working in a very confined space at the moment.
 
I'm about a 45-minute drive north of San Francisco, but my first ED is on display at the Palace of Fine Arts in San Francisco for the next couple of weeks. After that, he'll be packed away in storage again.

Shoot me a message when you're going to be in town. It'd be nice to share horror stories.

When I was scaling up the NECA figure, there were a lot of things we took to calling "figure-isms." These were little inaccuracies that made the character practical as an action figure. For example, the feet on the figure are way too big and the gun barrels are way too long. Otherwise, it was pretty much spot-on as far as I could tell.

In hindsight, I probably would've been a lot better off with fewer people helping. Since I had to concentrate on actual money-making projects, I turned the ED-209 into a teaching project. I essentially invited everyone who'd ever asked me to show them how to do any of the processes involved. So I'd spend half a day showing someone how to lay up fiberglass or run the vacforming machine, or whatever, then they'd spend the next two days doing something I could do in about three hours, then I'd never see them again. There were about a half dozen core people that were really awesome and useful, but I spent so much time babysitting some of the less able folks that the help might not have been all that helpful. There were days where I spent so much time answering questions and putting out fires that the only thing I could get done myself was to occasionally sweep the floor.

The best thing to come out of it though, was that I managed to add a few new folks to my crew that I can count on when important, rushed projects come along.
 
I'm about a 45-minute drive north of San Francisco, but my first ED is on display at the Palace of Fine Arts in San Francisco for the next couple of weeks. After that, he'll be packed away in storage again.

Shoot me a message when you're going to be in town. It'd be nice to share horror stories.

When I was scaling up the NECA figure, there were a lot of things we took to calling "figure-isms." These were little inaccuracies that made the character practical as an action figure. For example, the feet on the figure are way too big and the gun barrels are way too long. Otherwise, it was pretty much spot-on as far as I could tell.

In hindsight, I probably would've been a lot better off with fewer people helping. Since I had to concentrate on actual money-making projects, I turned the ED-209 into a teaching project. I essentially invited everyone who'd ever asked me to show them how to do any of the processes involved. So I'd spend half a day showing someone how to lay up fiberglass or run the vacforming machine, or whatever, then they'd spend the next two days doing something I could do in about three hours, then I'd never see them again. There were about a half dozen core people that were really awesome and useful, but I spent so much time babysitting some of the less able folks that the help might not have been all that helpful. There were days where I spent so much time answering questions and putting out fires that the only thing I could get done myself was to occasionally sweep the floor.

The best thing to come out of it though, was that I managed to add a few new folks to my crew that I can count on when important, rushed projects come along.

If its still there when I am over I will go take a look and a bunch of photos.

I will be flying out on the 28th, doing work stuff until the 3rd of March (Thursday) at Alameda offices which I think is near where instructables is, but I should be about on the Friday and the Saturday.

I don't do this stuff for a living, I work full time and do this in the evenings, weekends and time off work, which is why its been slow going recently. I have had to learn fibreglassing got a mate to come up and help me for a couple of days and teach me to glass, I'm still slow compared to him but I expect faster than some of the "help" you had, I had a couple of people try and help me but I ran in to the same issue, I was babysitting them to make sure it was done right and it wasn't actually helping so I have stopped accepting help and instead just expect the project to be done when its done.

I have learnt a lot about the processes doing this, and your right about the figureisms I too made my guns shorter, I don't recall if I made the feet smaller or not. I may not have done, but thats not a big concern, if they look wrong I can easily redo them.

I had to buy a CNC Router table to do some of the stuff, I looked in to a craftsman like you have but they wont support it here in the UK so I had to take other routes. Looking at getting a Laser cutter soon but thats probably after this projects finished.
 
the Last 2 nights I managed to finish another 2 sections of the body mould, got about another 6 sections until its finished, then my issue will be grinding the flanges as I cant get it through the door to take it outside and it kicks up a ton of dust. going to take some thinking.

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Had a busy weekend so didn't get much done, managed to finish the centre section of the bottom of the body which is something.




Next sections will be the sides where the elbows for the gun pods will attach (hard to tell when its upside down), hoping to do those in one large section.

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