Machined Terminator endo arm progress thread

Yo Marty! I sent you an email a week or so ago; let me know if you didn't get it and I'll resend it. Following this thread with GREAT interest!!

Hey, man!
Yeah send it again if you would. Ive been using my work email so much the old one gets neglected. With any luck I'll have access to a CNC machine here pretty soon so it may be full aluminum kits for RPF members at some point:thumbsup
For now I'm tweaking out the details and getting the process down. The parts in the pic are V3.0 (in other words, I screwed up 2 versions so far). The "large" sections that make up the finger between the 1st and 2nd knuckle are being redone since im convinced I milled the slots 1/16 too wide. All together I have about 30 finished parts.
There's been a lot of this process:
-Make the part based on research and "info"
-Compare it to all available reference
-Notice it looks off from one particular angle
-Remake the part with alterations
-Say "Eureka! So thats what they did"
- Move on to next part, or part of the same part and likely notice something else and have to start over again anyway.

But thats how it goes I guess:cool

You said something about kits. How much do thin none will end up?

Yup, the master (in the pics) is spoken for and...not cheap:)
BUT WAIT!
There will be kits available once everything is done. I'll head over to the JY thread and go into more detail here soon. PM for details.
 
Nice work SwampDonkey!

One question about your tools, is that a Ryobi bandsaw I see there? I have been looking into getting one to make life cutting MDF easier. Would you reccomend these bandsaws?
 
Hi, I was wondering if you would be able to help me gather some information on how much this certain T2 endo arm I have could be worth...

Here is the description:

Made by Timeless Collectibles in 2000 (I'm pretty positive that's the right year). It is a full scale T-800 Endo Arm propped on a base of skulls and debris. Includes Terminator 2: Judgment Day The Ultimate Edition DVD, plaque that reads, "Presented to Movie Gallery... Thanks for having a big hand in our Ultimate DVD launch," plaque reading "Artisan Entertainment." All is enclosed in a fairly large, rectangular glass case. There is a small plaque that reads, "Timeless Collectibles... T-800 Endo Arm... This exact 1:1 scale endo arm and section of charred earth have been meticulously reproduced from actual Terminator 2: Judgment Day screen used props. Only a limited number have been made in this format exclusively for Artisan Entertainment, under direct supervision of noted special effects artists." It is also numbered 006, but I have no idea how many were made--obviously less than 1000.

If you have any idea on pricing or how exclusive/rare this is, I would really appreciate the help.

Thanks.
 
Nice work SwampDonkey!

One question about your tools, is that a Ryobi bandsaw I see there? I have been looking into getting one to make life cutting MDF easier. Would you reccomend these bandsaws?

Oh yeah, should work great for MDF. Goes through aluminum with ease (with proper blade) and you cant beat the price.
 
Hi, I was wondering if you would be able to help me gather some information on how much this certain T2 endo arm I have could be worth...

Here is the description:

Made by Timeless Collectibles in 2000 (I'm pretty positive that's the right year). It is a full scale T-800 Endo Arm propped on a base of skulls and debris. Includes Terminator 2: Judgment Day The Ultimate Edition DVD, plaque that reads, "Presented to Movie Gallery... Thanks for having a big hand in our Ultimate DVD launch," plaque reading "Artisan Entertainment." All is enclosed in a fairly large, rectangular glass case. There is a small plaque that reads, "Timeless Collectibles... T-800 Endo Arm... This exact 1:1 scale endo arm and section of charred earth have been meticulously reproduced from actual Terminator 2: Judgment Day screen used props. Only a limited number have been made in this format exclusively for Artisan Entertainment, under direct supervision of noted special effects artists." It is also numbered 006, but I have no idea how many were made--obviously less than 1000.

If you have any idea on pricing or how exclusive/rare this is, I would really appreciate the help.

Thanks.


Sounds like a rare find! Is it posable or one solid piece? Some pics would be great:)
 
Hey guys! I ended up scrapping all the parts you see in the pics thus far. I realized that to do this right, I had to utilize CNC. An expensive and difficult proposition, but the results are WORLDS ahead of anything I could do by hand. The conversion of the milling machine is a huge (for me) project on its own. It took months to get it working right, and a few more to learn how to design and produce parts with the thing. Im using a trial version of CamBam to sketch out the parts and generate toolpaths:

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These were particularly tough, as they are more sculptural than machined. I measured the carples in crossection, then modeled the profile in cambam, then cnc milled the profile at 3 points on a piece of bar stock. This was then put in the lathe, correctly offset from center, and turned to size. The part was then sanded while still turning on the lathe to soften the odd oval shape found on the carples:

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Questions, tips, or comments are very welcome:)
 
Oh man, you've almost got walking dead fingernails! Clean those puppies! The build looks great, but you fail personal hygiene.

;)
 
Oh man, you've almost got walking dead fingernails! Clean those puppies! The build looks great, but you fail personal hygiene.

;)


I took those after wet-sanding aluminum with 1000 grit and Wd-40 and that crap soaks into your hands in ways that are beyond the grasp of human understanding. I'll pay attention to this in the future for photographic reasons, but the idea was to get "in progress" shots throughout the day while doing the work.
 
EQ - leave him be! Those are a skilled machinist's hands (although I'm surprised all the finger are there :lol). If I saw shiny clean hands and manicured nails, I'd suspect someone else was doing the work! (just busting on ya, EQ! :p )
 
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Well, things are moving along nicely. I had a real breakthrough that will vastly improve the quality of the product, but more on that later. I got a great deal (free) on some ultra high quality solid carbide lathe cutters. Infortunatrly the holders for these are expensive and rare in 1/2" shank, which is the largest my machine will handle. So I decided to make my own holders.

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Now the first thing I did with my fancy new cutters was tear into a piece of hard tool steel. I needed a slitting saw, and just so happened to have a bunch of the blades laying around. So I turned a chunk of 1" steel down to 5/8" with a flanged end, drilled and tapped, then BOOM! Slitting saw.

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I finished off some details on the knuckle joint, using a machined slug to ensure it was in the proper spot when the epoxy cured.

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With these pieces glued in place, I can drill and tap for 1/16" cap screws set with lock-tite. The heads of the screws will then be milled flat and be virtually invisible. I just wouldn't trust any kind of glue to hold such critical parts together.

Next up, we have some finger tips. This is a tricky one since they are tuned on the lathe, which is pretty straightforward, then the round profile has to be cut, then then crescent shape cut with a standard end mill, then the inside curve needs to be done with a 1/8" ball-nose end mill.

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And AH, now the good stuff. These will be kits, and are offered in the JY (though I probably shouldn't say more than that in this thread). Anyway, with the first couple of deposits I was able to get a vibratory polisher, likek they type used to clean bullet casings and clean parts. I did a bit of research and found that rounded ceramic media do what I needed it to do, though I consider it lucky that everything went as planned.

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I threw in a couple of scrap parts for a few hours and WOW! All tool marks were removed and I was reminded of the flawless finished found on pistols and rifles. I assumed the ceramic had simple abraded the blemishes off, but the calipers showed no change at all, though the readings were now more consistent. Im guessing what happens is the media impacts the surface thousands of times like tiny hammers, massaging imperfections back to a flat surface. Keep in mind that these were scrap pieces I pulled from the junk bin,

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I was also able to get a jewelers torch so I can do any brazing that may be required. Some of the pistons look like they've been brazed, but some experimentation is in order.
Below is the 1/4" plate that will serve as the base of the palm.

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We'll climb that mountian when we get there. Adn here's the obigatory shot of how it look all put together so far (notice no fingertips as those are being done today).

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