R2D2 Styrene build

[shsims]

OK now time to change direction, I've completed a warhammer

and I've completed a Jedi

Its time to start building something that I've wanted to try for a long time. I'm going to build a working R2D2 droid.

With the assistance of http://astromech.net/ and the R2 builders club which I am both a member of, its finally going to happen.
I have sent a couple of months doing research on the who, what, why and cost of this and have decided to build R2 using styrene plastic. The main reasons are that I have access to a local dealer, Farco Plastics www.farcoplastics.com they carry both the 3MM and 1MM styrene that I will use at a good price. The other reason is because of another's hard work, Dave Everett has put together a complete set of blueprints, pics and how to's to get it built (which members have access to). I expect this project to take at least one to two years to complete So , now by following Dave's plans and and with the assistance all those that answered my questions during research, here we go.
Dave plans comes with 1 to 1 scale blueprints of the frame so I want to Staples and had them print to scale for me, the cost was 2.65 per sheet and there were seven sheets. total cost 18.55

Next was buying the styrene, its come as a 4x8 sheet and the 3MM cost was 58.00

 

[shsims]

The styrene sheet was bought and by cutting out the blueprints and using a non permanent adhesive spray The prints were placed on the plastic to maximize space for cutting.

 

[shsims]

I also built a router table to assist in cutting all the rounded pcs

 

[shsims]

OK stared cutting all the strait edge pcs (lots)

 

[shsims]

Ok for the round frame pcs there are measurements that you find in the how to guide. You measure the correct distance from blade and drill a 3mm hole through the router table. You then cut out a rough circle around the print and styrene, drill a 3mm hole through the center of print and using a 3mm bolt, put it through print and plastic .put bolt through pre drilled hole. The router has a strait cutting bit on it so when you turn it on it cuts though the styrene and you rotate the pc around and you get your perfect circle the size you want

after taking my time to be sure I had it right and not mess it up.(2 days) I got the main frames pcs cut out

.
I told you there was lots of pcs

OK there are a few more things to cut and drill then I can start putting the frame together

 

[karmajay]

Wow great job cutting! I did not trust myself so I bought some laser cut body pieces. Just received them last week.

 

[Sith Lord]

It's a fun project, isn;t it? I'm nearly finished my R6 droid out of styrene. Not sure I would want to do it a second time though. LOTS of styrene cutting......

 

[shsims]

I was scared to death cutting those parts, 1st time for anything like this, I probably measured each pc 3 or 4 time to be sure

- - - Updated - - -

hey send me any assistance ya can Ill take it

 

[knnyjay]

Subscribed !!! Looking forward to your build and will be following with interest :thumbsup

 

[Sith Lord]

hey send me any assistance ya can Ill take it

Spend more time getting the chamfers on the angled parts right. Save time taking shortcuts (like I did), you'll spend waaay more time putty, fill, sand, putty, fill, sand....

 

[shsims]

Ok, started gluing frame together as instructions say. As I did I used an Idea from another member, used L brackets to keep uprights strait

Here is lower section finished

Cut out the slot for coin slots and drilled holes for doors and glued on second section

 

[shsims]

Ok got part of of the 3rd section complete

 

[shsims]

Off to work, Probably a few days before any more gets done

 

[Gonkdroid]

Keep up the pics and step by step this is looking great and on my radar, i may try my luck at a R5.

 

[Halliwax]

thats a lot of work. i always respect the styrene builds. there is so much work involved. and i think personally the hardest route to go when doing a r2 build because everything is hand fabricated. i could never pull it off with my shaky sausage fingers. much respect sir!

 

[cjchiu]

What type of glue is used for a styrene build like this? 2-part epoxy? Contact cement?

 

[Halliwax]

if the styrene is ABS you can use acetone

 

[GaryArm]

Acetone is the perfect adhesive to use on styrene as it welds the plastic together rather than just gluing it, any excess liquid just evaporates leaving a very clean joint, and the weld is much stronger than the plastic around the joint.
I have used Acetone or even automotive paint thinners to join styrene projects for over 20 years with great success

 

[CT7567]

This is looking stellar. I've always wanted to try my hand at an astromech build but it seems like such a daunting task.

 

[Sith Lord]

Haven't heard of people using Acetone before....

I used Weldon 3 and it seems to be the glue of choice over on Astromech builders.

What glue are you using shsims?