Pee-Wee's Big Adventure Clown

[crimsonghost]

Starting to look like an animated mechanical advertising robot finally! Here are some photos, with my second clown behind it for comparison.

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Thanks for the warm welcome Duckbutt, It looks like you're knocking that build outta the park quickly. It looks good.

 

[billy baloney]

Wow!, I'm away for a couple a days and there's all kinds of good stuff goin' on!,

Welcome, crimsonghost, Thanks for all the likes, I can't wait to see your clown!

Your skeleton and mechanism are looking Awesome DB,

Your new suit looks fantastic!, PWF , way to go guys!

 

[Duckbutt]

Just a few updates, lost most of the weekend to rain (sigh) ..

Milled that damn sliding piece finally. The outermost dimensions are about 1.5" x 0.875" x 0.825" ; the protrusions are around 0.5" each way.





Cut the arm to length and angled it based on my other clowns. This will obviously take adjusting once he's in the suit.



Wired up the motor and plugged it in, waves like a champ. I should have taken a video, since I then promptly stripped the set screw threads while adjusting the arm (hence the dangling in the photo above). Will have to redo that tomorrow, besides putting on speed nuts and greasing everything ..

 

[PeeWeeFan]

Wired up the motor and plugged it in, waves like a champ. I should have taken a video, since I then promptly stripped the set screw threads while adjusting the arm (hence the dangling in the photo above). Will have to redo that tomorrow, besides putting on speed nuts and greasing everything ..

Instead of a set screw, you may just want to use a spring pin all the way through. Two set screws may also be an option if there is not enough material to support a spring pin.

 

[Duckbutt]

Yep, I actually picked up more roll pins tonight thinking it might get this finished quicker (even though I like the ease of set screws). The original plan was to try one set screw with a flat milled on the rod, then go to two if it needed it. Impatience will probably win out this time

 

[crimsonghost]

I have all the wood cut for the base and lower body. I will start assembly tonight. Does anyone know the RPM of the original REX motor ? Im looking at Dayton motors that are cheaper (8-13 rpm). Also, since I don't have a clown and im building from scratch does anyone have dimensions for the motor plate ? Thanks in advance !

 

[Duckbutt]

Are you trying to copy the original down to the details? Or just make it functionally the same? Certainly with modern robotics parts or 3D printer, this thing could be made simpler. You can also simplify things like the backing plate shape. I just have a particular desire to stick to the original design (even though it makes things complicated).

From stopwatching it, my motor runs about 10 - 10.5 RPM. You could call Rex and ask for the spec'd speed, but they were jerks when I called and tried to ask about the motor. The backing plate is about 11" x 5" (I saved my template to upload someday .. if you're interested I can scan it in).

 

[PeeWeeFan]

I have the entire mechanism modeled, but I have not had time to make the drawings. I was hoping to get one built first to make sure it worked.

 

[PeeWeeFan]

I hadn't thought of replicating that one (instead doing a custom one, similar to the custom X1 bike badges). But it shouldn't be too bad to scan and make some if you're interested in the original badge style.

DB, I thought that I would let you know that I currently have a subscription to www.vectormagic.com, although I will probably only keep it for another month. If you scan the base plate, I can put it in a vector format. I'm sure that's the format they would want for silkscreening.

 

[PeeWeeFan]

I spoke with Mr. Malcolm on the phone this evening. Super nice guy! He definitely loved making the advertising robots. He got out of the business due to more and more city ordinances. He sold his company to someone else who started using inferior materials. He specifically mentioned the plastic used for the face was not suitable for sunlight - which I think we have all figured out! He said his robots always had the nameplate. The mechanism was largely copied from a 1950s Santa Claus that he had. I asked about the silkscreening on the faces. He stated they originally airbrushed and handpainted them. He then found a Japanese-owned company that silkscreened the face onto the plastic prior to vacuum forming. He said the company was incredibly talented. He basically built them for $200 (1980s dollars) and sold them for $700. He mostly dropped them off at businesses and told them to try them out for a week. He then would come back to pick them up or collect a check. He said that he never had a company not purchase it! Back in the '80s, he said there were streets in California where one of his robots would be found on almost every block. The clowns were originally shipped in refrigerator-sized boxes.

Definitely a very creative and business-savvy guy!

 

[billy baloney]

That's incredible, you actually spoke to the "creator"!, the puzzle is almost complete, did he mention where he sourced the hair?

 

[Duckbutt]

Cool stuff! How did you find his contact info? I never managed to get a reply in Google+, although I don't know if I sent my messages correctly.

If you're able to talk to him again, I'd be interested to know if he has any molds or materials still, and how he sculpted and got the molds made for the head. And if he had anything to do with the Pee Wee clown. And where he got the hair, wheels, and other materials. And ...

Someone mentioned inviting him to the thread, that would be even better.

 

[PeeWeeFan]

It took a little bit of sleuthing to find him, but the dots finally all connected.

It very much sounded like most startup companies. He basically found the cheapest materials wherever he could. A lot of the plywood was scrap lumber. He made some purple gorillas just because a guy offered him a truckload of hair for a good price.

As for the molds and such, everything went when he sold out. He doesn't even have one of his own robots. He said they appeared in magazines and TV quite often during that time, just because they were so popular. He did make some custom animatronics for customers as well. He said the custom work actually began to interfere with regular production. I did not ask specifically about the head sculpt. If I make contact again, I certainly will.

He did say to call him if I have any other questions. Although, it sounds as if he's moved on. I have known a few entrepreneurs over the years, and he certainly fits the type. He went on to do other advertising and private investigation work.

 

[Duckbutt]

The silkscreening before vacuum forming blows me away, I didn't think that was an option (either because it would look bad or take a million tries to get the placement right). I guess I have no choice but to make silkscreens now for my heads.

Did he mention where he lives now? I know the article said he was from Texas. I'd love to get my Custom Displays clown autographed if he's anywhere close.

 

[PeeWeeFan]

The silkscreening before vacuum forming blows me away, I didn't think that was an option (either because it would look bad or take a million tries to get the placement right). I guess I have no choice but to make silkscreens now for my heads.

Did he mention where he lives now? I know the article said he was from Texas. I'd love to get my Custom Displays clown autographed if he's anywhere close.

I did some more research into silkscreening before vacuum forming. It is technically called distortion printing. It's been around for quite some time. Years ago, they would simply screen print a grid pattern onto the plastic prior to vacuum forming. Once vacuum formed, you could easily see where the grids end up on the 3D surface. You simply place your features in the desired grids prior to vacuum forming. With a little luck and a few trial pulls, you could determine proper feature placement. With computers now, the placement is of course much better.

I ddin't ask specifically where he lives, but he seemed to indicate he lived east of Indiana.

 

[crimsonghost]

I rescued a waving santa today for $70. He is missing the stand and the head is crushed in a couple of spots. The frame, motor. And mechanism is all there. I started taking off the costume and noticed the motor plate is different. And the frame appears to be a little different than the clowns. Ill take photos and meaurements as i go once i figure out how to add them.

 

[Duckbutt]

Is that a Custom Displays Santa? Or some other kind? I'm dying to know what my Custom Displays clown looks like on the inside, but i haven't gotten the nerve to open him up yet (the suit is completely sewn shut). I suspect there will be some differences in the construction and mechanicals.

I usually use Tapatalk to upload photos from my phone since it's easy.

 

[PeeWeeFan]

I rescued a waving santa today for $70. He is missing the stand and the head is crushed in a couple of spots. The frame, motor. And mechanism is all there. I started taking off the costume and noticed the motor plate is different. And the frame appears to be a little different than the clowns. Ill take photos and meaurements as i go once i figure out how to add them.

Interesting. I would not have guessed the motor plate to be different. I look forward to the pics.

 

[PeeWeeFan]

You may have actually bought the Santa that Mr. Malcolm borrowed the mechanism design from. I'm guessing it will work just fine though.

 

[crimsonghost]

I did manage to get some photos. There are noticeable differences to the lower body, and minor differences in the motor mounting plate. I found a date on a newspaper clipping used to give form to one of the arms. It is dated 1958 I believe. I did plug the motor in and the mechanism worked well even though the main support rod for the upper torso is bent forward a bit.