ROGUE ONE K-2SO Puppet Build

Discussion in 'Star Wars Costumes and Props' started by DrscifiProps, Jun 28, 2016.

Tags:
  1. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    I took the K2 skeleton out to my local 501st squad meet today. Had fun showing him off to my friends and practicing walking around. He's holding up great.
     
    Amon, chefhawk and smoothrat like this.
  2. goldenhawk

    goldenhawk Well-Known Member

    Trophy Points:
    685
    Awesome build. What PVC parts did you use to make the knee and elbow joints?
     
  3. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Glad your enjoying the build.
    Here's a link to the kit I bought. http://www.spiderhillpropworks.com/S...-Kit_p_19.html

    I got one kit from the Halloween store I posted about. 9 total spider joints.
    2x shoulders
    2x elbows
    2x knees
    2x ankles
    1x connection point


    Perhaps I should keep a parts list in the first post to help people out.
     
    Bigturc likes this.
  4. cckaiser2

    cckaiser2 Active Member RPF PREMIUM MEMBER

    Trophy Points:
    461
    How's the build coming along?


    Sent from my iPhone using Tapatalk
     
  5. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    He's still coming along. This was a long work week but I'm excited to continue on the feet/legs this weekend. I'm usually doing some image research each night to find new angles and details. Turbosquid has a great 3D model of K2. Almost perfect and lots of detail. https://www.turbosquid.com/3d-models/3d-x-star-wars-k-2so-droid/1096528

    I watched jechts twitch stream where he built his pvc pipe hands. Asked a lot of questions. May use the same concept for K2.

    Here's a video of him flexing the fingers: https://www.instagram.com/p/BPdW2V7D6qM/?taken-by=jechts

    It's raining a lot here in CA so may be harder to do foam glue on the weekend but we will see. I'm starting to count weekends instead of days until my deadline as they will be my main building times. 12 weekends left
     
    Last edited by a moderator: Nov 8, 2018
  6. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    :) just went through a hundred posts on tumbler celebrating K-2SO. I'm all pumped to get him finished and start having fun.

    Photo shoots, smart * lines and some great puppeteering. I can't wait!
     
  7. kman

    kman Well-Known Member

    Trophy Points:
    536
    Following this. Great work!
     
  8. goldenhawk

    goldenhawk Well-Known Member

    Trophy Points:
    685
    Thanks for sharing that info. A kit like that makes building a robot easy. I should try to build the Proxy Droid from the Force Unleashed. Since I wear the Galen Marek costume at RL appearances.
     
    DrscifiProps likes this.
  9. TheBlackPhantom

    TheBlackPhantom Member

    Trophy Points:
    192
    This is my favourite build right now, keep up the great work! I think a puppet is a fantastic idea and you don't see a lot of cosplay puppets either. I think that's what makes this such a unique build besides the fact that I've yet to come across another K2-SO. I wouldn't mind trying my hand at this or something similar!
     
  10. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Thanks!

    Here in California i've seen a Grevious puppet done before, using his cloak to hide the puppeteer. K-2SO is so new we have yet to see him done anywhere. But that doesn't stop some of us from trying to make him a reality.
     
  11. TheBlackPhantom

    TheBlackPhantom Member

    Trophy Points:
    192
    OH YEAH, I saw that guy one time online! I plan to go to more conventions here in Central Florida, where right now I'm an hour away from DisneyWorld ironically lol
    Maybe I'll see some more puppet suits at this year's MegaCon!
     
  12. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    It's been difficult to find good conditions to cut foam and apply glue with all of the rain we've been getting in California this week. But I had a breakthrough today that will put me back on track. A good friend of mine has given me an extended loan of his bandsaw! Now I can cut out my joint pucks, and do many shaping cuts that I couldn't do with just a razor blade.


    [​IMG]

    It has an ingenious wheeled base that can drop down to lock the corners into place. I can't wait to fire this up and start cutting foam. Tomorrow i'll glue together the sandwich layers of the joint pucks and template out the rest of the feet. I've also moved my deadline up two weeks to April 1st. I'm going to try to get K-2SO ready for his first con. We shall see if I can make it.

    Keep building

    -Darren
     
    Amon likes this.
  13. Stinkape

    Stinkape Active Member

    Trophy Points:
    341
    Looking forward to your progress, great job !!!!
     
    DrscifiProps likes this.
  14. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    I'll be cutting and gluing foam tonight. Might livestream on twitch, we'll see. https://www.twitch.tv/drscifi
    But I just wanted to take a moment and thank everyone who has posted encouraging words on this build. I just can't wait to take K2 out and see the look on kids faces.
    And someone needs to start building K2's brother, I can't be the only one with this droid around. The world needs a good dose of salty droid.

    -Darren
     
  15. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Amon, hun buns and PropReplicator2 like this.
  16. goldenhawk

    goldenhawk Well-Known Member

    Trophy Points:
    685
    Looking forward to seeing this project finished.

    i was thinking what you said about the guy hiding in the cape of the Grievous puppet. Maybe you need to dress as Cassian and walk behind K-2SO.
     
  17. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Time for another update! T-8 Saturdays until my April 1st self-imposed deadline :eek

    A new exciting piece came today. A micro wifi camera for my POV system. Purchased from Amazon. https://www.amazon.com/gp/product/B01IR2AFNO/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 This little guy is exactly what I need. It has a 4 hour battery but that can be extended with a cell phone usb charger. It offers a self generated wifi network that I can connect an ipod touch or ipad mini to for my screen. I'm planning on mounting it either inside his eye or in the cheek greeblies.

    32280123230_a3d25919a6_c.jpg

    Pretty clear image for wifi transmission. It creates it's own password protected network for me to connect to. And can even record or capture stills to the ipad.
    32536985921_6bc61b6d03_c.jpg

    Here is the box it came in but I also put a link above to the exact model I purchased. Only cost $28~
    32280123770_0806931ae5_c.jpg


    Now most of my progress has been on the joint pucks. I thoroughly mapped out exactly how much area I needed cut up into foam and how thick I was building up to. This ended up using my entire 2' x 5' 10mm foam sheet and I'm still a little short for the center pieces for the knees. Hopefully the 8mm foam will stretch farther as it covers the bones instead of having to make up thickness.
    32474277706_bc45d03860_c.jpg

    Measure twice, cut once.
    32474277646_18e16f6ff1_c.jpg

    The largest pieces will be for the outer knee pucks. 5" wide and 50mm (5 layers) thick. This block will make 4 of them.
    31703217433_eb3bb1a9f9_c.jpg

    90% of the puck blanks are ready to be glued. I worked very hard to make sure I didn't waste any foam. Speaking of foam, this is from TNT Cosplay Supply.
    http://tntcosplaysupply.com/store/p29/EVA-_38_Foam.html Which is great for it's low price and being smooth on both sides.

    31671413504_5c87547c3a_c.jpg

    I coated the joining sides with barge contact cement.
    31718487723_6bd24475f9_c.jpg

    And left the pieces pressed together for a few hours while they dried.
    32151484080_46ab3d4bf7_c.jpg

    The trickest part was the large 5 layer pieces. Had to glue 2 pieces together (x2) then coat the center slice on both sides and sandwich it all together.
    32489576766_d88efb96de_c.jpg

    I livestreamed on my twitch channel while working on the glue. Had fun talking about the process and my design. I plan on doing this more through the rest of the build. https://www.twitch.tv/drscifi Follow me here on twitch for future broadcasts.
    32530495275_b8006291d7_c.jpg

    I punched out some of my colored floor foam for an adhesive test with the barge. I needed to see if it would work between the pipe PVC and the foam.
    32407997641_3b55b0f3aa_c.jpg

    Once the glue dried as it should these were sufficiently sturdy enough for me to use Barge contact cement on the inner discs that will support the outer skin foam.
    31803570093_05c5ab1eda_c.jpg

    I'm also working a lot on templates. Sketched out the dimensions for the back cog and bar panel. I'll mount this on corner magnets so I can remove it to access the internal electronics such as the speaker aker, the eye light batteries and cameras.
    32462379862_58f2c6dca7_c.jpg

    These wireless base station antenna will be used for K-2SO's back antenna.
    32615798915_e56d3341dc_c.jpg

    It feels like his abs and hips are too small but I think once he's put together it will all balance out. That is my greatest fear is I'll build a part and it will not feel in scale with the rest of the droid.
    32462381212_dfa9be46e5_c.jpg

    I won't count the hours i've spent staring at K2's but.
    32462358882_71484635eb_c.jpg

    I'm also ordering a scalloped blade for my borrowed band saw.
    4091a114p2-a04al.png
    I'm getting it from McMaster-Carr. Which if you've never heard of is an INCREDIBLE site for parts, tools, just about anything.
    Just go check it out for an hour or 3, i'll wait. https://www.mcmaster.com
    I saw on a Tested video https://www.youtube.com/watch?v=XuBo_lHvgjQ that a scalloped blade is best for cutting through foam and not leaving a rough edge.


    Thank's @Frank Ippolito and @nchan for the info.

    I'm ball parking getting the skin done by the end of February so I can focus on sealing, paint and weathering in March. And still need to 3D Print the head.

    More updates coming next week.

    Keep making

    -Darren
     

    Attached Files:

    Last edited by a moderator: Nov 8, 2018
  18. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
  19. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    It's been a while since I posted. But I was waiting on my scallop bandsaw blade to cut the foam, and I'm so glad I waited. It was difficult to be patient and wait for the proper tools. I really wanted to start cutting out my joint pucks but I think I would have ruined them with the wood bandsaw blade.

    I templated out based on my joint plans which you saw in my last post.
    32474277706_bc45d03860.jpg

    Again drawing on the book wrapping paper which had a 1/2" grid on it. I made the Knee, Elbow, Ankle and Wrist templates.
    32694965466_64b33fd3d7.jpg

    Here I'm making sure my 2" mirrors will fit inside the foam cut outs to create the "hollow" effect. Same for all of the joints. I have 2" mirrors for the smaller three and 2.5" mirrors for the knees.
    31921263763_23de481673.jpg 31921261553_649ef95508.jpg 32694962356_d34b830592.jpg 31921261233_090d30ff4b.jpg


    I traced everything out using silver sharpie on my foam stacks I glued earlier. Each stack is made out of 10mm foam layers joined together with Barge contact cement. By using the templates as a mask All I need to do is remove the silver edge to be right along my cut line.

    32355537700_7655b4d1ee.jpg 32694962216_abe696bd6a.jpg

    Again repeating the process for the wrist, ankle, elbow and knee. The ones I crossed out the middle circle is to remind me not to cut out the inner circle. These are the 40mm blanks that will be trimmed around the spider joint.
    31892113804_fa394cc327.jpg 32161193144_73551513ab.jpg

    Cutting day is here! I've changed the wood saw blade out for my scallop blade. That was a harrowing event. Always respect your power tools for the moment you don't they will hurt you. I made sure the saw was unplugged and followed the manual exactly to add the blade and calibrate it.

    32119437564_9ecca9374a.jpg

    Just image its a self-cutting knife on repeat forever! Don't get your fingers near this.
    32850928672_d965eb10b6.jpg

    This shows the difference between the two bandsaw blades I have. The lower was using the wood blade, the top using the foam scallop blade. Night and Day!
    32808915192_ac36efd2ab.jpg

    I cut pucks from 20mm to 50mm, being sure to remove all of the silver mask to make the circles the right diameter. This is two 40mm pucks and they came out great. They look like an 80mm stack cut at the same time!
    32850930942_86106c443c.jpg

    And repeat over and over for each one. Here are the wrists.
    32964940696_d79d49d2a9.jpg

    This is a knee or elbow. They are only 1/2" difference so hard to tell.
    32850931372_4e72ba368e.jpg

    I live streamed some of my work on Twitch.tv/drscifi. And will continue to do so as the project continues.
    32850931012_c582500742.jpg

    Now with everything cut out I trimmed the middle out of a few end pieces for tests. I still need to cut 90% of them out but I may drill out some of it. I need to find a balance between the bandsaw and sanding. These are not sanded on the inside yet but I want them to be relatively smooth.

    32624448040_808a768b51.jpg

    This is the first look at the "hollow" effect I'm going for with the mirrors. I'll still need to see it with the whole arm in place but I think the illusion will work. Or at least look better than solid joints.
    32191662673_c38d414dbe.jpg

    This is the ankle. You can see the 20mm end caps with the 40mm center blank. I need to work out the angles each joint will move between before I trim the center blank to allow for the movement.
    33007035105_ed34a801ca.jpg

    I've added a spacer on the knees for this picture as I haven't made the center 40mm blanks for the knees yet. I ran out of 10mm foam so I need to order some more.
    32191663033_300bd39968.jpg

    Here's the elbow pice placed over the spider joint.
    32162056164_ec163393db.jpg

    I'm holding the 3 slices together and the middle one is jutting out but you get the idea of how the joint will look. I'm very happy with how these pices came out.
    32851661682_33363c82b9.jpg


    My next design step is for the control linkages for the hands. I believe I will make these out of mdf or wood. This sketch isn't quite to scale but outlines how the finger tube lines will run from my glove to the hands. I want to keep as much of this hidden inside the arm. I also need to finish/start his hands.
    32625193580_188ea39d10.jpg

    Tomorrow is a holiday so I'm going to try to get a lot more done on either hand design/construction or getting the feet templated, cut, formed and starting on the legs.
    But still, patience. I don't want to rush even though I'm on a deadline. He will get done when he gets done.
    I also need to send my 3d head files to my friends with printers to get that moving.

    40 days left!

    Thanks again everyone for your support of my K-2SO puppet build. Please follow along at https://www.twitch.tv/drscifi if you want to watch while I work on K2.

    -Darren
     
    Last edited by a moderator: Nov 8, 2018
    TinyTim, NathansPROPS, cjchiu and 2 others like this.
  20. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    HANDS! So in my research I've found two designs for K-2SO's hands. The first I'll call the prop hand and you see this design in the arm extensions Alan had on set. You will also see this on the black series toy and the big figs. It has a more sharp angle wrist area with a boxy palm. This also has the oversized thumb coming up from way in the back of the palm.

    33102718795_7a36b05eaf.jpg

    The other version you see I'll call the CG hand and is what K-2SO has in the actual film. His fingers are a little more proportional.
    32287513953_bf812af6a2.jpg

    You can also see that his thumb is a more realistic length with the wrist area being curved and less boxy. There is also a rectangular panel on the back of the hand with an oval towards the wrist. This is the version I will be making for the puppet.
    32246741173_577824a795.jpg

    I sketched out the dimensions on my gridded paper. You can see how I started with the prop hand design before switching to the CG hand design. A 1" pipe T will be the base of the fingers.

    33062242785_8bf85851cc.jpg

    The fingers are made up of nested PVC pipe. It is called sharkbite pipe at Home Depot and is very thin. I didn't know HD carried pipe this thin until researching it. It's a little hard to find but found on the same aisle as the bigger PVC pipe. The fingers uses 1/2" finger spans with 1/4" knuckle pieces. Now this is the measurement of the inner diameter, so the overall size is not what is printed. They ended up being the following dimensions.

    1/4" pipe .24" inner / .375" outer
    1/2" pipe .84" inner / .608" outer

    The 1/2" pipe gets a 45*ish cut on both ends to allow the 1/4" pipe to pivot.
    32246266463_6afbc63285.jpg

    I cut out the finger spans. Here are the measurements of each segment. The thumb will be 2" pieces, plus the longer mounting base that connects it back to the wrist pipe.

    32287841583_0c59aea174.jpg

    I labeled everything by Letter/Number to keep it all organized.
    32680135280_6d4daca838.jpg

    I first made the "C" middle finger as it was the longest. All cuts are just eyeballed.
    33020019766_059112c25c.jpg

    A bacon cooking tray works great to keep the parts from rolling away on me.
    32246268993_7e71b93674.jpg

    I picked up a spool of 16 Gauge wire to act as the hinge points.
    33099073615_c07f0d4b9b.jpg

    This was a thrown together test digit. With the elastic down the back to open the finger and nylon cord down the inside to pull it closed.
    32972128641_8d61ff9193.jpg

    When you have to make a lot of something, make a jig. This helped me stay consistent on the cuts.
    32972128781_0a9776f696.jpg

    After fitting one half of the 1/4" pipe I trimmed it to size and took the corner off to let it pivot more.
    32283969993_87719bba85.jpg

    Everything is temporary as I won't be able to do final assembly until the whole arm is pieced together. The reason for this is when I cut the tendon cord It will need to reach all the way from K2's fingertips to my control glove fingertips. And I don't know that exact distance yet.
    33057406346_9f69d59265.jpg

    1 finger down, 9 to go.
    33057406126_17accbdaed.jpg

    I've finished the 4 main digits of the right hand. I've learned a lot. It's very difficult to keep the fingers straight and not crooked. I need to remake some of digit "C" to keep it straight. I also shortened the 1/4" pieces a little to make sure the fingers don't over extend open or curl up. But I'm overall very happy with how it's coming.
    33057406466_77032f3c92_c.jpg

    I'd be remiss if I didn't mention a fellow cosplayer and maker for introducing me to this design. https://www.instagram.com/jechts/ is using this technique for a giant pair of videogame character hands. https://www.instagram.com/p/BPYgDzGDkyZ/?taken-by=jechts He also pointed me to a youtube video by Indy Mogul of a prop build he did for the hands. These sources were very helpful in designing K2's digits.



    I'm 35 days out at this point and i've started to set some deadlines for each remaining weekend to keep myself on track. I only have 5 weekends and I can't use all of them to finish K-2SO. I'll be focusing on his feet and legs this first weekend as they don't require much innovation, just patterns, cutting and gluing. Now that my joint pucks are done I can keep those dimensions in line.

    I've been patient as I work along, doing things well and not rushing. But I need to step it up like I did while working on my Star Wars Stormtrooper armor. I worked 2 solid months doing at least SOMETHING every night to get that done. This project will require the same dedication to complete.

    So expect more posts here on the RPF and more livestreams on twitch.tv/drscifi as I work to finish K-2SO.

    Oh, and go check out my friend @GEEK1138 K-2SO statue. http://www.therpf.com/showthread.php?t=271894It looks AMAZING! Oh what I wouldn't give for a 3D printer.

    Also, this build thread has reached over 10,000 views! We could buy our own ship for that!
    Thank you everyone for your support and encouragement.

    -Darren

    33102718795_7a36b05eaf.jpg

    32287513953_bf812af6a2.jpg

    32246741173_577824a795.jpg

    33102718795_7a36b05eaf.jpg

    33062242785_8bf85851cc.jpg

    33102718795_7a36b05eaf.jpg

    32287513953_bf812af6a2.jpg

    32287513953_bf812af6a2.jpg

    32246741173_577824a795.jpg

    32246266463_6afbc63285.jpg

    32246741173_577824a795.jpg

    33062242785_8bf85851cc.jpg

    33062242785_8bf85851cc.jpg

    32287841583_0c59aea174.jpg

    32246266463_6afbc63285.jpg

    32246266463_6afbc63285.jpg

    32287841583_0c59aea174.jpg

    32680135280_6d4daca838.jpg

    32287841583_0c59aea174.jpg

    32680135280_6d4daca838.jpg

    32680135280_6d4daca838.jpg

    33020019766_059112c25c.jpg

    33020019766_059112c25c.jpg

    33020019766_059112c25c.jpg

    32246268993_7e71b93674.jpg

    32246268993_7e71b93674.jpg

    32246268993_7e71b93674.jpg

    33099073615_c07f0d4b9b.jpg

    33099073615_c07f0d4b9b.jpg

    33099073615_c07f0d4b9b.jpg

    32972128641_8d61ff9193.jpg

    32972128641_8d61ff9193.jpg

    32972128641_8d61ff9193.jpg

    32972128781_0a9776f696.jpg

    32972128781_0a9776f696.jpg

    32972128781_0a9776f696.jpg

    32283969993_87719bba85.jpg

    32283969993_87719bba85.jpg

    32283969993_87719bba85.jpg

    33057406346_9f69d59265.jpg

    33057406346_9f69d59265.jpg

    33057406346_9f69d59265.jpg

    33057406126_17accbdaed.jpg

    33057406126_17accbdaed.jpg

    33057406126_17accbdaed.jpg

    33057406466_77032f3c92_c.jpg

    33057406466_77032f3c92_c.jpg

    33057406466_77032f3c92_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
  21. LeClubNerd

    LeClubNerd Well-Known Member

    Trophy Points:
    536
    Keep up the awesome work. :)
     
    DrscifiProps and PropReplicator2 like this.
  22. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Aaaaand now I'm going in a new direction with K-2SO's hands.
    I came across AlphaTech686 build of Grommash from WOW. He's working on fingers using linkages instead of tendons.
    I like the idea a lot. I'll still have a tendon from my control glove to the K2 hand but the closing of the fingers will be done by linkages.

    Here's some test footage of his linkage design.


    The Grommash finger side. Using 1/8" PVC sheet with Chicago screws.
    32739314660_648069a38c.jpg

    The Grommash finger edge.
    32306068523_55182dde54.jpg

    For the longest digit on the hand I'm going with 3" - 2" - 2" for the lengths between knuckles.
    33121634375_1301699963.jpg

    I decided to make a foam board prototype to test the concept before I invest in plastic sheeting.
    33079863456_55b5498fa2.jpg

    Finger digit layers.
    32276512484_067c9eb854.jpg

    Blueprint and prototype. This is very rough with just bent wire for the joint. The final fingers will have Chicago screws.
    33079863366_91fc74b3c2.jpg

    I need to adjust the linkage bars to allow the finger to bend more. I believe it has to do with the ratio of the pivot joint to the linkage joint.
    32739143640_b77a2ac4bb.jpg

    Plan A PVC pipe and Plan B PVC sheet.
    32965148812_6669e47a2f.jpg

    So far I think this is the better way to go. I won't even need to add too much foam to the fingers as they already look very robotic. K2's fingers are more squarish anyway, and I would need to turn the cylinders into more square shapes to make them work anyway.

    Always continue your research into your project. You never know when you'll be making changes.

    - Darren
    35 Days

    32739314660_648069a38c.jpg

    32739314660_648069a38c.jpg

    32739314660_648069a38c.jpg

    32306068523_55182dde54.jpg

    32306068523_55182dde54.jpg

    32306068523_55182dde54.jpg

    33121634375_1301699963.jpg

    33121634375_1301699963.jpg

    33121634375_1301699963.jpg

    33079863456_55b5498fa2.jpg

    33079863456_55b5498fa2.jpg

    33079863456_55b5498fa2.jpg

    32276512484_067c9eb854.jpg

    32276512484_067c9eb854.jpg

    32276512484_067c9eb854.jpg

    33079863366_91fc74b3c2.jpg

    33079863366_91fc74b3c2.jpg

    33079863366_91fc74b3c2.jpg

    32739143640_b77a2ac4bb.jpg

    32739143640_b77a2ac4bb.jpg

    32739143640_b77a2ac4bb.jpg

    32965148812_6669e47a2f.jpg

    32965148812_6669e47a2f.jpg

    32965148812_6669e47a2f.jpg
     
    Last edited by a moderator: Nov 8, 2018
  23. Friendly flyer

    Friendly flyer Well-Known Member

    Trophy Points:
    536
    Cool! The linked finger seems promising!
     
  24. mmhnc

    mmhnc Well-Known Member

    Trophy Points:
    635
    I want this idea, it seems like it will look more accurate.
     
  25. cjchiu

    cjchiu Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,086
    Wow. Impressive. Seems like fingers are really complicated no matter which direction you go.
     
    PropReplicator2 likes this.
  26. LeClubNerd

    LeClubNerd Well-Known Member

    Trophy Points:
    536
    Man, that is some fast work right there lol :)
     
    DrscifiProps likes this.
  27. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511

    I really like how the hands are coming together. Picking up the plastic sheeting from Home Depot today. I found a 1/16th thickness so that should help keep them thin with all of those layers and linkages. The tricky thing is getting the angles of the pivots down. My prototype was half successful but without the right angles it won't bend right and close.

    Today will be getting more materials. I also want to finally finish the feet patterns.

    -Darren
    34 Days
     
    Last edited by a moderator: Nov 8, 2018
    cjchiu likes this.
  28. kman

    kman Well-Known Member

    Trophy Points:
    536
    Curious: Have you considered using 3D printed hands? I don't like 3D prints for a lot of the purposes they are applied to, but this sort of intricate linkage seems right up their alley.

    If you don't have one, I know there are public libraries that sometimes offer them. Plus friendly local RPFers who might be willing to help. :)
     
  29. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    I've thought of it. But at this point it would take me longer to design and find someone to print then to make out of the pvc board.
    I say that now, we will see after I've made 1 full finger.

    I'm going back and forth between printing the head and making it out of foam. Might try foam first.
     
  30. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Finally some progress on the feet. I've progressed more on actually getting foam on the skeleton in the past 24 hours than the past 24 days. The slowest part of this phase is making the templates. Cutting them out of the foam is easy (thanks to my awesome bandsaw). But making them takes time.

    33074184861_70999c84e2.jpg

    After laying out one-half of the foot walls I mirrored it to create the whole piece.
    33160267686_d1f1df8af3.jpg

    This was scored and had the back edges cut along the folds.
    33213811686_cb586ae78f.jpg

    The tricky part is to make each edge line up with the foot plate.
    32819527690_1c0aed84b1.jpg

    Everything is lining up nice. Here is where the ankle joint puck will go.
    33160267566_5f7051bf87.jpg

    I found if I reversed the washer in the joints to the bolt side instead of the nut side it has a lower profile and doesn't stick out.
    32872192480_4d47b30e76.jpg

    This is important when mounting the side pucks with their mirrors. I have a flat surface to adhere to.
    32872192090_26d7076596.jpg

    I realized I didn't need to cut out the whole circle for the lower ankle plate.
    32357374304_4b8c12dd0e.jpg

    By just cutting out a half moon it has a nice snug fit to the joint.
    32411648194_a8904119f1.jpg

    This is one of my favorite shots of the entire build.
    32872191690_320b8a9113.jpg

    The outer pucks will be glued to the bottom plate and have a few mm clearance from the top plate.
    32411646934_e14c64ef8d.jpg

    I added two stops with screws to keep the ankle from bending beyond where I want it to. If it goes too far the foam edges will smash into each other and damage the leg. I will do this with all of the puck joints. Ankles, Knees, Elbows. The wrists won't rotate on that axis.
    32872202890_5592973c29.jpg

    33128040771_d7c2715fbb.jpg

    I moved all of my K2 parts down to our single car garage. Almost like having a workshop.
    32872190410_165f366837.jpg

    Fabricated the lace covers top piece of the feet. I won't be scoring the outside edges of the folds this time. I want to see what it looks like as I can't take that action back.
    32411642984_9157a393ba.jpg

    The lace covers are a little thick but when the toe part is joined I think it will balance out.
    32411640554_30fb119879.jpg

    Put some hidden pink foam inside the walls for strength. These are now glued together. That is a harrowing part of any project. No Take Backsies.
    33099307482_d1e0eb91e1.jpg

    Even more nerve-wracking was inserting the joint in. The PVC is held by friction but the lower joint plate is glued with contact cement to the foot.
    32411643074_20572473eb.jpg

    With the lace cover on.
    33126731251_6c7987847e.jpg

    I've templated out the top, side, and bottom of the toe part. Just need to cut it out and glue it together and the feet will be done.
    Oh, and finish the ankle joints.
    32872188960_682dbfd747.jpg

    I am very happy with my progress made today. If I can have a dozen or so days like today I should have K-2SO done on time. I need to put at least 2 hours into him every night to feel comfortable with my progress. I only have 5 of my weekend days available between today and April 1st.

    27 days left

    - Darren
     
    Last edited by a moderator: Nov 8, 2018
    NathansPROPS, wedge86, Yrien and 2 others like this.
  31. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Went back down after the kids were asleep and finished cutting out the rest of the toe pieces.

    32443428833_78a3c64e99.jpg

    I was smarter this time and stacked the 4 edge pieces together to cut them at the same time.
    32875044300_d0c6b925e1.jpg

    Each toe is made of a top, two sides and the bottom. I should be able to glue these all together in about an hour tomorrow.
    33216626466_f683d7703b.jpg

    So the feet will be done tomorrow. I'll have the ankles done for sure and hopefully the leg templates complete.

    Still 27 days left.
     
    Last edited by a moderator: Nov 8, 2018
    NathansPROPS, Yrien, mmhnc and 2 others like this.
  32. LeClubNerd

    LeClubNerd Well-Known Member

    Trophy Points:
    536
    Keep up the great work sir
     
    DrscifiProps likes this.
  33. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Another night and more progress.
    I glued together the cut seam for the ankle joint outer pucks. I also trimmed out the center core of the other 3 copies.

    33258785016_10c9df8fba.jpg

    Created an inlay for the mirror.
    33258784906_0cc6259b97.jpg

    This way it sits flush and is easier to mount the puck to the joint.
    33299580725_f1b4428267.jpg

    The toes came along nicely. Glued the sides to the top first. Wrapping the edges around.
    33299579915_8a4beffb76.jpg

    Testing the fit.
    33171468251_967b42ba46.jpg

    The under piece presses out on the walls so the overall shape is trapezoidal.
    32916851250_40e4d78452.jpg

    Everything is flush on the bottom.
    32484884393_9c78c6004e.jpg

    Feet are 90% complete. Just need to trim the lace cover a little around the toe so it can bend some.
    33258785586_ce9a6f412f.jpg

    I'll also glue the lace cover down and trim the back corners for some nice angles on the foot.
    32916851370_486795e9aa.jpg

    Very happy with how this turned out, and it's not even painted and weathered yet!
    33258784916_6e3473a0b0.jpg

    More progress tomorrow.
    26 days left

    -Darren
     
    Last edited by a moderator: Nov 8, 2018
  34. Bengrim09

    Bengrim09 Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,781
    Your progress is great, your work is outstanding, love the way it's coming together, can't wait to see the hands come together, keep up the great work
    26 days left !!! :eek
    you can do it :thumbsup
     
    Last edited by a moderator: Nov 8, 2018
    DrscifiProps likes this.
  35. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Working on my calendar.
    15 days left
    Scheduled out my evenings and remaining weekends. I have roughly 65-71 hours left.
    More progress pictures going up this weekend.
    Legs are coming together and the head is being 3D printed.
    I've also ordered everything I think I should need to finish except for the paint.

    Let's do this!

    -Darren
     
    Last edited by a moderator: Nov 8, 2018
    Bengrim09 and Amon like this.
  36. MooCriket

    MooCriket Master Member

    Trophy Points:
    3,366
    Looking great so far!
     
    DrscifiProps likes this.
  37. Bengrim09

    Bengrim09 Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,781
    good luck my friend looking forward to the updates
     
    Last edited by a moderator: Nov 8, 2018
  38. SofaKing01

    SofaKing01 Master Member

    Trophy Points:
    3,660
    Positive thoughts and fingers crossed! :)
     
  39. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re-elect Mayor Goldie Wilson, progress is his middle name!

    I received my Cassian rank bar for my officer. Even though I hope to go out with a Cassian cospayer most of the time I thought it would be fun to have my rank match his disguised officer rank on Scarif.

    33358937481_ca7fb17fbb.jpg

    The head has been printed! My friend Steven over at Inland Empire Armory printed my K-2SO head for me. I just supplied the filament and he took care of the rest. All while graciously allowing me to hound him for progress pictures every day.
    33365601321_5292ab172d.jpg

    Head half with the support core.
    32650510394_fd8d388704.jpg

    Deeper and taller.
    32650515474_ff4eface8f.jpg

    Only half a brain on this droid.
    32650515634_df29ee6ca1.jpg

    Printing the wrap around lower head.
    32673231983_0e2a0fc779.jpg

    All of the pieces coming together.
    33122348800_8040ee2afa.jpg

    A very loose test fit. Figuring out how this all goes together.
    32730825093_d5b5a5f651.jpg

    All of the pieces. I ended up not needing the two core blocks from the center of the jaw. I'll also be modifying the under side to allow the pan/tilt head to operate.
    32730825523_f97a325d6b.jpg

    Taping everything together.
    32701641934_e730336892.jpg

    It looks great. I have the mouth plate on backwards here but this gave me a feel for how the head will look. I'm planning on mounting my spy camera in the cheek area.
    32730825823_0640effd64.jpg

    Flipped around the mouth plate. Everything looks good and fits well together.
    33504442626_5cef5a3fec.jpg

    I plopped the whole thing on top of the pan/tilt head to see if it could handle the weight. Was very happy it can. The pan/tilt head will be relocated inside the head but it can pan and tilt!
    33504936536_f676b4dbb3_o.gif

    Close up of the cheek area.
    33504442876_ee86af33a2.jpg

    I'm planning on attaching the camera battery here to the front of the pan/tilt. The cable should reach for the camera but not have the battery weight on the motor.
    32701642574_4052ebdb7d.jpg

    I also plan to put the camera logic board here where I can see the display light out through one of K2's light up greeblies. I just need to be sure I can still turn it on/off.
    32730827013_a566867d80.jpg

    Cut away some of the internal structure so the pan/tilt head had more room. Panning isn't a problem, but with the pan/tilt inside the head I needed more space for it to tilt up and down.
    32730828003_8a47dcd42f.jpg

    I temporarily placed the leftover chin core inside the head to get the pan/tilt placement.
    33504444156_4e92042c30.jpg

    The pan/tilt sits just below this layer of the head.
    32730828463_ba534c85d5.jpg

    This means I need to cut away a lot of the lowest layer, the underside of the head.
    33504444996_1636bf63fe.jpg

    I'm keeping the front part which will have some of the chin glued to it. The rest will be discarded. I'll create a rim following where the piece was out of a strip of foam. Perhaps put some black cloth in.
    33545495215_ea68c12b82.jpg

    Covering the cut point with foam.
    32701644914_268572acc2.jpg

    Cut out K2's eyes from a milk jug. Still need to wire up the lights.
    32701644834_2c9ef40766.jpg

    My garage will not be hosting a care for the next week. This will save me setup time as I work on K2 every night.
    33504445256_bd6338a305.jpg

    12 days!

    Expect more updates here.

    -Darren

    33358937481_ca7fb17fbb.jpg

    33365601321_5292ab172d.jpg

    32650510394_fd8d388704.jpg

    32650515474_ff4eface8f.jpg

    32650515634_df29ee6ca1.jpg

    32673231983_0e2a0fc779.jpg

    33122348800_8040ee2afa.jpg

    32730825093_d5b5a5f651.jpg

    32730825523_f97a325d6b.jpg

    32701641934_e730336892.jpg

    32730825823_0640effd64.jpg

    33504442626_5cef5a3fec.jpg

    33504936536_f676b4dbb3_o.gif

    33504442876_ee86af33a2.jpg

    32701642574_4052ebdb7d.jpg

    32730827013_a566867d80.jpg

    32730828003_8a47dcd42f.jpg

    33504444156_4e92042c30.jpg

    32730828463_ba534c85d5.jpg

    33504444996_1636bf63fe.jpg

    33545495215_ea68c12b82.jpg

    32701644914_268572acc2.jpg

    32701644834_2c9ef40766.jpg

    33504445256_bd6338a305.jpg
     
    Last edited by a moderator: Nov 8, 2018
  40. MooCriket

    MooCriket Master Member

    Trophy Points:
    3,366
    Now, that is what I call progress!
     
    DrscifiProps likes this.
  41. Tumbler

    Tumbler Active Member

    Trophy Points:
    262
    Amazing work! Lost track of this thread and glad to have found it again. Epic build.I love it.
     
    DrscifiProps likes this.
  42. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    I think I know what was giving me builders block tonight. There are so many components to K-2SO that need to be fabricated my mind is all over the place. I need to sequence this out. "Don't over design the shoulder joint sleeves before the arm and torso are done." Tomorrow I'm going to list out the components and give this build some order.
    This is also beneficial in that the more progress I see the more excited I get to finish. Time to dig deep.

    11 days left.
     
    oota goota and smoothrat like this.
  43. karmajay

    karmajay Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    I'm working on a Shoretrooper outfit and my deadline is also a week before Celebration so I know how you feel! :)
     
    DrscifiProps likes this.
  44. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    As I mentioned yesterday I've taken all of the components/steps for each portion of K2 and written them out on index cards.
    Head, Torso, Harness, Arms, Legs & Props are the main categories.

    It's a lot, but bit by bit it's coming together.

    33541512696_1d28c7791f_c.jpg

    Ran to Home Depot during my lunch and picked up a few supplies. Grabbed filler primer and bondo putty for the 3D printed head. This will help smooth it out for painting and detailing.
    I also purchased screw eyes for guiding the hand linkages, two wooden planks for the hand puppet plates, some latex gloves and PAINT!
    Picked up my 2x Rustolium primer paint and the black high heat BBQ paint. I've seen others who paint K2 use this color and it has that flat metallic look I'm going for.
    33425267742_966b099f34.jpg

    I also want to make one of these Death Star data cassettes as a prop for K2. This isn't my build but an example of what I want to do. A little foam, some CD spindle pieces and wires and I'll have a nice prop for the tall guy.
    33425265442_1ef6cc39e6.jpg

    My back harness arrived. With so much of K2's weight being placed on my lower back, I don't want to hurt myself. So far the layers are building up. The back brace, then the chest harness, then the Imperial Officer tunic.
    32767711413_7aeb10b988.jpg

    Did a lot of design work on the puppet hand plates. As I always say, there's a point in every project where scale matters. I've reached that point. This was my first design, determining how far I'll be from K2's back and center line. I changed tactics once I realized that his elbow will be almost at my shoulder height. I need to be able to keep his arms at a neutral stance without bending my wrists too much.
    33425711882_05c1996f20.jpg

    So I shifted to this design. The panels are closer to the elbow and connect at a 30*-40* degree angle. This lets his arms hang down at his sides without my bending my arms or wrists. But I can still pivot my wrist and make him reach up for higher objects etc. I still need to dial in the exact angle but it will be close to this. Screw eyes and the drip line hose will create the channels for the tendon lines. They will be long but should not loose grip due to the drip line sleeves.
    32769903103_cfdec75308_c.jpg

    More work and hopefully some fabrication tomorrow night.
    10 Days Left

    33541512696_1d28c7791f_c.jpg

    33425267742_966b099f34.jpg

    33425265442_1ef6cc39e6.jpg

    32767711413_7aeb10b988.jpg

    33425711882_05c1996f20.jpg

    32769903103_cfdec75308_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
  45. Dogless

    Dogless New Member

    Trophy Points:
    17
    Wow! Great project and a fun read too. Good luck hitting the deadline DrscifiProps.
     
    DrscifiProps likes this.
  46. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Made another part run during lunch. This time to the local hobby store. I had the thought that a turnbuckle would be good to have in the finger control cables. This way I can make it two cables with a tensioner instead of one long cable from finger tip to finger tip. Less room for error and I can replace part of it if needed.

    32769903103_cfdec75308_c.jpg

    I found these tiny Traxxas wheel struts. They are tiny turnbuckles and perfect for this application. One side is adjustable up to 1/2 an inch. I can pop out the bearings and have a solid ring to tie the control line to.
    33438901882_0cd4983a8f_c.jpg

    I also found some thin foam packaging at work that was being tossed out. I want to loop this into a cylinder and stuff the elastic tubes on the shoulders and hips for more rigidity.
    33595297865_135a4fcac4_c.jpg

    A full night in the garage to be sure.

    9 Days left

    32769903103_cfdec75308_c.jpg

    33438901882_0cd4983a8f_c.jpg

    33595297865_135a4fcac4_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
    NathansPROPS, cjchiu and MooCriket like this.
  47. karmajay

    karmajay Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    Your countdown in your updates keeps freaking me out!
     
  48. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Very productive today. Spent about 8 hours on K2 tonight.

    I'm modding a Nerf gun to use as his blaster, keeping it light.
    33579490866_97b1264c5a_z.jpg

    I removed the internal mechanisms, and the trigger. I'll later slice off the top arm and add a scope. This blaster is cool in that it has a detachable barrel. I'll keep that added part with the orange safety tip. But the rest will be black for closed area photo shoots.
    33237141120_7c72f3484f_z.jpg

    Started to template out the puppet plates.
    33620427895_89f5193557_z.jpg

    This was the trickiest angle to get right. I needed K2's arms to be in a natural position when I have my hands in a natural position. But also be able to fully extend them if I want to.
    33463734832_c819c8331b_z.jpg

    Working on mounting the finger tendon guide tube to the puppet plate.
    33491225061_fc4574a247_z.jpg

    Most of my work tonight was on the hands. I added some extra pipe to the core structure T joints. Drilled out the 4 finger holes and sanded them to the proper size with my dremel.
    33620427815_c537e17a94_z.jpg

    A test fit of the finger material.
    33579491796_ce3e86efc5_z.jpg

    I cut out all of the right hand finger pieces and wired up another finger. Only 4 more fingers to wire. These are turning out straighter and faster than my first attempts.
    33237141690_3d38e944f0_z.jpg

    Got the digital version of Rogue One on Amazon. So watched that in the background while working. Pausing frequently for more screen shots.
    33237160380_55b006f00f_z.jpg

    Just look at this beautiful picture of K2's back!

    33491448301_ec945c98ab_z.jpg

    Loosely ran the tendon cord down one finger for testing. The elastic will also run down the inside with the whole thing capped with 2mm foam.
    33237426940_5ee1fd7aa5_o.gif

    Cut all of the 10 tendon guide tubes so they can stretch out and straighten before installation.
    33620441355_498cd2f9ca_z.jpg

    Finished finger holes.
    32777921244_f79008d1ba_z.jpg

    I also extended the bicep piece. Top is old length, bottom is new.
    33491225511_fe9440eac8_z.jpg

    Can't wait to meet you K-2SO.
    33237161040_4a52b5aee3_z.jpg

    8 Days Left

    33579490866_97b1264c5a_z.jpg

    33237141120_7c72f3484f_z.jpg

    33620427895_89f5193557_z.jpg

    33463734832_c819c8331b_z.jpg

    33491225061_fc4574a247_z.jpg

    33620427815_c537e17a94_z.jpg

    33579491796_ce3e86efc5_z.jpg

    33237141690_3d38e944f0_z.jpg

    33237160380_55b006f00f_z.jpg

    33491448301_ec945c98ab_z.jpg

    33237426940_5ee1fd7aa5_o.gif

    33620441355_498cd2f9ca_z.jpg

    32777921244_f79008d1ba_z.jpg

    33491225511_fe9440eac8_z.jpg

    33237161040_4a52b5aee3_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  49. LeClubNerd

    LeClubNerd Well-Known Member

    Trophy Points:
    536
    8 days good sir...i wish you the best. I'm falling behind on my builds..probably because i'm reading yours :)
     
    DrscifiProps likes this.
  50. Mechanized2400

    Mechanized2400 Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    You're a beast! This is some amazing work, indeed.

    Loving this build
     

Share This Page