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
    Thank you. Most of that work was between 9pm and 3am
     
    Tumbler likes this.
  2. Mechanized2400

    Mechanized2400 Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    Hahaha story of my life, man.
     
  3. kman

    kman Well-Known Member

    Trophy Points:
    536
    Doesn't everyone other than students and actors get everything fun done during those hours? LOL
     
    Tumbler likes this.
  4. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Cut out the puppet plates while on my lunch break today. It's amazing how fast the work is when you use the right tool. Tried to start cutting these with my dremel last night and got nowhere. Jigsaw took 3 minutes.

    32791019464_b7633d9e45_c.jpg

    Also went by Home Depot on the way home. Got some bigger screw eyes for guiding the draining pipe. Also found some hinges and 3/4" pipe for the finger controls. I think I have everything I need to assemble tonight. We shall see.
    33504530141_76a9a53829_c.jpg

    8 days left and doing great!

    32791019464_b7633d9e45_c.jpg

    33504530141_76a9a53829_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
    NathansPROPS likes this.
  5. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Well I am definitely in con cosplay crunch mode. The last two nights i've worked from 9pm to 3am. Making great progress but feeling a little tired.
    With the puppet plates cut out I marked where they would be slotted into the forearm. This narrow rectangle was cut out with my dremel.

    33597791246_1d8b3e965d_z.jpg

    Held mostly by friction I ran a bead of hot glue along the edge and ran 3 screws through the PVC pipe to secure everything nice and tight. This joint would undergo a lot of stress and needed to hold fast.
    32795786874_22c2086a8c_z.jpg

    I mocked up the position before final glueing.
    33254663850_59ce5a467b_z.jpg

    Ready to paint.
    33638265495_a874922dac_z.jpg

    Primer coat.
    33638265425_724b613264_z.jpg

    Flat black coat. I painted at this step because the wood would be under a lot of hardware. I'll touch the hardware up with more black paint but this way no wood grain will ever show through.
    33254661820_6d5446e618_z.jpg

    Ready for hardware.
    33482004552_51e9f013b8_z.jpg

    I finished the rest of the fingers for the right hand. And did some elastic and tendon tests.
    33597789866_152d0db030_z.jpg

    I ended up not re-doing any of the connection bars but instead ran the tendons and elastic on the outside of the finger.
    33254662010_75cc6f5afa_z.jpg

    Starting plans for the finger controls. Riveted 3/4" PVC rings to these hinges to make finger holes. I ended up replacing all of these with 1" pipe rings. The 3/4" was too narrow with the rivet poking inside.
    33597789946_51acf9f4a5_z.jpg

    I keep my first knuckle just before the hinges.
    32795830224_1b5d59ccc2_z.jpg

    Starting to come together. I finished adding the 1" pipe to the finger tips. Added screw eyes to guide the tendon pipes. Also added some 1" elastic looped around the plate to hold my hand down. And some 2mm foam to protect my knuckles from the hinges.
    33638267965_a1cf94cd37_z.jpg

    The elastic is tight but needs to be in order to have the plate move.
    33482005672_3b510ec79f_z.jpg

    Each line was far longer than I would need. Always over do it on home runs.
    32795786804_960515d894_z.jpg

    I started to add the tendon pipes. This worked out great with the screw eyes and cable tacks.
    33270887050_426920a822_z.jpg

    I love the detail on this picture. This is where months of planning and design work pay off.
    33498116212_81fa07e8f8_z.jpg

    The gap will have the small turnbuckles to add tension between the finger ring run and the K2 hand run lines.
    32841351563_25a4224734_z.jpg

    I need to keep both arms on at the same time. It's a both or nothing situation now as one arm is too heavy to stay on by itself without balance.
    32841350583_15a271b501_z.jpg

    Added the clear tubing on the bottom of the digits for the tendon line. Elastic is attached along the top. Lots of tape but it will be covered in 2mm foam.
    33525558561_2691cb8b3e_z.jpg

    This has the left pointer finger completely wired up.
    33498115482_737accb36d_z.jpg

    To quote "The Princess Bride"
    You just wiggled your finger, thats wonderful!

    I need to move back the screwed down cable covers a little to allow the turnbuckle to slide back another inch. This will let the finger curl completely. But the concept has paid off. It's been a long few days but immense progress has been made.

    33654639285_8ed6a44981_o.gif

    I called it early tonight to catch up on my sleep.
    Tomorrow I plan to wire up the right hand and make all of the connections for both arms. Then I can begin encasing all of the mechanisms in foam.

    I'll still need to use all of my free time for completing this project, but I have a plan and i'm sticking too it. I also practiced moving the puppet arms around while harnessed in and the range of motion is great. I'll still need to practice but it's working just as I had intended it.

    6 days left Here comes Saturday!

    33597791246_1d8b3e965d_z.jpg

    32795786874_22c2086a8c_z.jpg

    33254663850_59ce5a467b_z.jpg

    33638265495_a874922dac_z.jpg

    33638265425_724b613264_z.jpg

    33254661820_6d5446e618_z.jpg

    33482004552_51e9f013b8_z.jpg

    33597789866_152d0db030_z.jpg

    33254662010_75cc6f5afa_z.jpg

    33597789946_51acf9f4a5_z.jpg

    32795830224_1b5d59ccc2_z.jpg

    33638267965_a1cf94cd37_z.jpg

    33482005672_3b510ec79f_z.jpg

    32795786804_960515d894_z.jpg

    33270887050_426920a822_z.jpg

    33498116212_81fa07e8f8_z.jpg

    32841351563_25a4224734_z.jpg

    32841350583_15a271b501_z.jpg

    33525558561_2691cb8b3e_z.jpg

    33498115482_737accb36d_z.jpg

    33654639285_8ed6a44981_o.gif
     
    Last edited by a moderator: Nov 8, 2018
  6. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Today was a day of progress and setbacks. I have a ton of pictures to upload but won't be able to post them until tomorrow.

    I glued together the 3D printed head and mounted the camera. But I put way too much bondo putty on the head so I need to sand most of it off.

    I found the perfect hardware for the eyes and wired those up.

    I finished the thumbs and began encasing the arms in foam. I've cut out the hand pieces and am ready to glue.
    Unfortunately the power switch on my belt sander has blown out. So that took us down. Fortunately I don't think I'm cutting through anything thicker than 1 sheet. It will just be a little slower.

    Head - 50%
    Torso - 10%
    Arms - 75%
    Legs - 40%
    Harness - 60%

    3 more days, can he do it!
     
    karmajay and mmhnc like this.
  7. karmajay

    karmajay Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    Are you going out of town the next couple of weeks? Celebration is 13-16th and I thought that was your goal.
     
  8. Captain Solo

    Captain Solo New Member

    Trophy Points:
    17
    Nice progress! I am a big fan of your construction!
    Cool idea with the hands! :)
     
  9. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Not going to Celebration. Wondercon in Anaheim is my target. Then next will be the SoCal RPF meetup.
     
    karmajay likes this.
  10. Tumbler

    Tumbler Active Member

    Trophy Points:
    262
    Great job on the hand mechanisms. Very clever and effective. Can you get enough cable pull with your finger to close up K2's finger all the way?
     
  11. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    They close about 70%-80%
    I'll later change his hands to be cables linked to a linkage driven mechanism. So a very small motion on the cable will close his whole hand. That's K-2.0
     
  12. kman

    kman Well-Known Member

    Trophy Points:
    536
    Ooh, awesome! Will you be there on Sunday? I'd love to see this thing in person. :)
     
  13. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Just Saturday. But I mostly built him for Con Appearances. I'll keep a calendar or "appearing next" section on my website. Http://drscifi.com
     
  14. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Well it's been a few days since i've posted pictures, I've been doing a few late nights in a row. It's so quiet at night and peaceful. My most productive time is between 9p and 3a.
    But here are the pics from Sunday - Tuesday night's work.

    I wired up the other 3 fingers on each hand using the mini turnbuckles. They worked great. I had to move the screwed down cable covers to allow them to shift enough.
    33691670156_3304c3ef34_c.jpg

    Time for some primer filler on the 3d printed pieces.
    33347679620_19a70fbc07_c.jpg

    Everything got a coat or two. It really helped smooth things out.
    33691669036_27d875ee30_c.jpg

    But i'll still need some bondo putty.... we'll get to that later :/
    33691668526_c16a0bf7d2_c.jpg

    No more fumes for me. Listen guys and gals, you NEED a respirator if you are using paint or glue, if you can smell it, you are breathing it in. If you don't have one, Get One!
    33691667876_57a64caae9_c.jpg

    Watching some twitch while I work. I've streamed some but no one seems to be watching while the world is asleep.
    33603388231_5bac6632c7_c.jpg

    If you do want to follow my twitch channel it's here:
    http://twitch.tv/drscifi

    Cut out the center cores for all of the joint pucks.
    32889665054_c39e5429d5_c.jpg

    Got pretty good with the bandsaw.
    33347678780_44b7f0a53b_c.jpg

    Storage, not drying.
    32889664954_5f3133d8b9_c.jpg

    Next piece to fabricate was the arm edges that touch the joints.
    33691666906_afc5bd0b14_c.jpg

    This is the elbow. Again the bandsaw makes quick work of the foam.
    33691666136_48b165d675_c.jpg

    Test fit.
    33691665716_150395a30c_c.jpg

    Glued in the two end shapes.
    33691665406_08e9dd41ab_c.jpg

    Cut some curved foam to add more glueable surface area.
    33347677920_0aee927c8b_c.jpg

    So I put two screws in the hinge to act as a stop so his elbows don't double back. In this picture the leftmost puck is glued to the top and the rightmost is glued to the bottom.
    33575955562_d72b3a4ddb_c.jpg

    I also figured out how to close the middle. I won't end up using the core pucks I cut but instead put either 2mm or 6mm foam in a ring around the inside on both pucks. With 2mm~ in the middle. It will cover most of the gap and pivot smoothly! Can't wait to get that installed.
    32889653414_20e5b359b8_c.jpg

    I'm very very happy with this joint. It's one thing to have a concept in your head, it's another to see it actually work! The screw stops keep the end pieces from touching and crushing the foam. Everything has tight clerances but nothing touches.
    33576369732_bd6b8aa6a5_o.gif IMB_uDHjmL by drscifi, on Flickr

    Counter sunk the mirrors in the ankle and wrist pucks.
    33691663366_ecab15ecaf_c.jpg

    The ankle pucks.
    33347677420_6c0120df44_c.jpg

    All joint pucks are done.
    32919148753_8f0307e8f8_c.jpg

    Another great build shot. You can really see the illusion work. It feels like the joint is hollow. It won't always look like this from some angles, but I love the slight of hand.
    32889663564_6364aa992c_c.jpg

    While wandering around Home Depot, as I tend to do. I came upon these nylon hose elbows.
    33691661546_702a3878b3_c.jpg

    I had tried just lighting K2's eyes with the 5 led's under the milk jug disc, but they didn't diffuse enough and just looked like he had fireflies in his eyes.
    I pushed one led up into the center and wrapped 4 around the back in a square.
    33575955042_6f6c2049c4_c.jpg

    The whole thing illuminates and disperses the light evenly.
    32889662064_ba3607848b_c.jpg

    Two eyes wired up with extra on the side. I might tuck the middle LED down on the bottom of the head as an indicator that the eyes are on.
    33347676250_408ebe5054_c.jpg

    With the right angle they sit flush on the support shelf inside the head.
    32919148433_d882a4e3c4_c.jpg

    And look AMAZING! Just what I wanted. K-2SO doesn't have Iron Giant glow eyes, he has irisis and pupils.
    32889662224_43a4a29bd4_c.jpg

    His eyes are more like rings, and actually shift as he looks around.
    32919676883_be1acd663a_o.jpg

    Wonderful.
    33691660326_280e832250_c.jpg

    In gif form.
    33603750501_d1d88ef09f_o.gif

    I drilled out the holes on this little side chip.
    33691659246_c5260da075_c.jpg

    It will let some of those extra eye LED's through.
    33691658346_64d5410e2f_c.jpg

    Time for super glue.
    33347675450_298476909d_c.jpg

    Did some streaming.
    32919146463_70e20e2ee0_c.jpg

    It was so fun to put this puzzle together.
    32919146353_29d3f51294_c.jpg

    Everything fits. Trying out a place for the spy camera.
    33603385371_cefe4f377e_c.jpg

    I'm going to moun the spy camera circuit board here so the power/status LED can be seen.
    32889660214_4b9f592798_c.jpg

    Might use this LED or might use the eye white ones. Which will probably wash this one out.
    33691657246_6b0254c7db_c.jpg

    Temp holding the spy camera in place. Again, when the head is black you won't see the ribon at all.
    32889658354_8bd6ec4d46_c.jpg

    Marking out a cut out to hold the ribbon when the two pieces are joined.
    33575953592_156fde1acd_c.jpg

    Trimming 3d Prints is interesting, you never know whats beneith the surface.
    33691654706_aa7053509e_c.jpg

    Perfect.
    32889658074_80c5de9300_c.jpg

    It sits flush.
    33603384221_9f2b1d1306_c.jpg

    Time for super glue.
    33691656026_144f8b7c76_c.jpg

    The lip shelf was a great clamp spot while the glue set.
    32919143433_3a5209ac60_c.jpg

    Two tusks
    33347673020_7a2a45b6df_c.jpg

    You can see how the filler primer really helps reduce or even eliminate the 3d print striations.
    32919141103_8cf1f864ff_c.jpg

    The head is in 3 pices at this point. The mouth plate/vocordor is one, the tusks and jaw is the second and the rest is the third.
    32889655934_bc1b124359_c.jpg

    Looking good.
    33691648566_6d9304753d_c.jpg

    Setbacks.
    So I've never done bondo putty to hide seams and 3d print striations before, and went a little overboard. It added some weight to the head and looks terrable. But lesson learned. Time to sand sand sand.

    33691648146_ec7cb1dc97_c.jpg

    Figured out how i'm going to mount the head. I'm building a small platform glued into the head made out of foam. REM (Rare Earth Magnets) will connect the platform to the pan/tilt. This way I can remove the head to install components etc but it will stay secure. No bobble head.
    33691647736_a78b1df7c2_c.jpg

    Ugh, added some more filler primer to try to cover up the clay. Welcome to stone golumn K2.
    33603381991_505b565523_c.jpg

    Jeeze, This was the low point of the build. Everything was so good up to now. But I pushed through and set this pieces aside. Time to work on something else.
    32919139613_d6a1422b5b_c.jpg

    The components of the inner mount. It straddles the "V" groove inside the top of the head.
    33347669590_2d52ab7f77_c.jpg

    REM magnets will go on this plate, though I need to lower it some.
    32919139273_22e128c358_c.jpg

    Thumbs! Time to finally get the inside of the hands complete so I can skin the arms in foam.
    33691646586_53319a5f75_c.jpg

    Working out the angle and placment of the thumb was tricky. Then mirroring it on the other side was even trickier.
    33691645306_de77d65912_c.jpg

    It wiggles a little, but you gotta have thumbs.
    33575951132_f489abcbbe_c.jpg

    The wired up hand.
    33603379061_626d2da315_c.jpg

    I hang the arms up on the chain link fense when i'm not working on thme. But seriously, I feel like IRON Man making his armor almost every day.
    33347666850_363cca4c33_c.jpg

    Yep, I'm Tony Stark.
    IronMan4045.jpg

    Same work bench. Time to start skinning.
    32919137213_6fdff9bcf6_c.jpg

    I cut out the palm/back of the hands. Sadly this will be the last pices my bandsaw cuts. As my second setback of the day the power switch started smoking. So the saw is kaput for now. Fortunatly I've already cut all of the stacked/thick foam I need. Everything else is 2mm, 6mm or 8mm. I should be able to handle that with my knife. Though it will be a little slower.
    33732249795_579a4dde10_c.jpg

    Glued in the wrist pucks. Had to move around the tendons some. For the wrists I do use the original concept center puck as this part doesn't pivot. The way he rotates is hands is to rotate his whole arm.
    32889652554_79faf114c3_c.jpg

    Scoring the top and bottom of the hands. Once I heat seal these they will open up some and look awesome!
    33732249835_26981a1c42_c.jpg

    Ready to glue, but it's 5am so time for sleep.
    33732249825_c1032e0cb1_c.jpg

    Whew, what an update. Only 3 more nights until Wondercon Anaheim! I can't wait.
    That's 69 more pictures of K-2SO.
    Now back to work for a couple of hours.
    Let me know if you want me to try streaming some on Thursday and Friday.

    33691670156_3304c3ef34_c.jpg

    33347679620_19a70fbc07_c.jpg

    33691669036_27d875ee30_c.jpg

    33691668526_c16a0bf7d2_c.jpg

    33691667876_57a64caae9_c.jpg

    33603388231_5bac6632c7_c.jpg

    32889665054_c39e5429d5_c.jpg

    33347678780_44b7f0a53b_c.jpg

    32889664954_5f3133d8b9_c.jpg

    33691666906_afc5bd0b14_c.jpg

    33691666136_48b165d675_c.jpg

    33691665716_150395a30c_c.jpg

    33691665406_08e9dd41ab_c.jpg

    33347677920_0aee927c8b_c.jpg

    33575955562_d72b3a4ddb_c.jpg

    32889653414_20e5b359b8_c.jpg

    33576369732_bd6b8aa6a5_o.gif

    33691663366_ecab15ecaf_c.jpg

    33347677420_6c0120df44_c.jpg

    32919148753_8f0307e8f8_c.jpg

    32889663564_6364aa992c_c.jpg

    33691661546_702a3878b3_c.jpg

    33575955042_6f6c2049c4_c.jpg

    32889662064_ba3607848b_c.jpg

    33347676250_408ebe5054_c.jpg

    32919148433_d882a4e3c4_c.jpg

    32889662224_43a4a29bd4_c.jpg

    32919676883_be1acd663a_o.jpg

    33691660326_280e832250_c.jpg

    33603750501_d1d88ef09f_o.gif

    33691659246_c5260da075_c.jpg

    33691658346_64d5410e2f_c.jpg

    33347675450_298476909d_c.jpg

    32919146463_70e20e2ee0_c.jpg

    32919146353_29d3f51294_c.jpg

    33603385371_cefe4f377e_c.jpg

    32889660214_4b9f592798_c.jpg

    33691657246_6b0254c7db_c.jpg

    32889658354_8bd6ec4d46_c.jpg

    33575953592_156fde1acd_c.jpg

    33691654706_aa7053509e_c.jpg

    32889658074_80c5de9300_c.jpg

    33603384221_9f2b1d1306_c.jpg

    33691656026_144f8b7c76_c.jpg

    32919143433_3a5209ac60_c.jpg

    33347673020_7a2a45b6df_c.jpg

    32919141103_8cf1f864ff_c.jpg

    32889655934_bc1b124359_c.jpg

    33691648566_6d9304753d_c.jpg

    33691648146_ec7cb1dc97_c.jpg

    33691647736_a78b1df7c2_c.jpg

    33603381991_505b565523_c.jpg

    32919139613_d6a1422b5b_c.jpg

    33347669590_2d52ab7f77_c.jpg

    32919139273_22e128c358_c.jpg

    33691646586_53319a5f75_c.jpg

    33691645306_de77d65912_c.jpg

    33575951132_f489abcbbe_c.jpg

    33603379061_626d2da315_c.jpg

    33347666850_363cca4c33_c.jpg

    IronMan4045.jpg

    32919137213_6fdff9bcf6_c.jpg

    33732249795_579a4dde10_c.jpg

    32889652554_79faf114c3_c.jpg

    33732249835_26981a1c42_c.jpg

    33732249825_c1032e0cb1_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
  15. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    FOAM! Let's cut it up.

    33378281840_e887af1142_z.jpg

    Starting on a small piece. The back Cog and Bars port with antenna. Already blue printed this out. It's a little rough doing curves without the bandsaw but I manage.
    32949970893_6b87a60d09_z.jpg

    Drawing in the locations of the lights.
    33721917266_f2cc1c4e6b_z.jpg

    Used some old wi-fi router antennas. I'll keep these unpainted to have a different texture.
    33378281030_0789eab842_z.jpg

    Need to make my lights red, tried making a gel with marker.
    32919728004_7b002861fb_z.jpg

    Then found some craft beads.
    33606281152_69418b6920_z.jpg

    Taped the beads over the lights.
    32949962433_ba52b04e5f_z.jpg

    Taped them down over the holes in the back.
    33721912646_c607914017_z.jpg

    Instant red lights.
    33762974115_fdb8bfa89c_z.jpg

    Prepped for paint.
    33633800711_84b4529530_z.jpg

    Painted piece. Just need to add the pin-striping and glue in the antenna.
    33606279062_446b460dde_z.jpg


    Added in the side pieces of the hand plates.
    33606280282_4f9865e840_z.jpg

    More plates.
    33762978485_baa6111be3_z.jpg


    Plasti-dipped the bottom of the feet for extra resilience.
    33633802861_dab1e6bf36_z.jpg

    I might add another coat later but the first coat is nice and thick.
    33633802331_072776c31b_z.jpg

    Finishing the forearms tonight. Used my cone maker program to get the angles right. 3" at the wrist, 4" at the elbow and 15" long.
    32919730744_a5c181585a_z.jpg

    Using the 31" big fig and the 6" black series I pulled the detail lines from the forearms.
    32949966413_337fc8ecc3_z.jpg

    The upper forearm will be an added piece of 2mm foam to add the stair step effect.
    32949966513_072d498770_z.jpg

    Heat sealing the foam, also makes it pliable for bending.
    33721914736_def6061329_z.jpg

    Scored the boxes which will open up with heat.
    32949968573_64bdcd22c4_z.jpg

    Prepping a slot for the control linkages.
    32919727094_3df8a8f5ab_z.jpg

    Added a 4" support ring to the end.
    32949961653_a84b5d211a_z.jpg

    Trimming the opening a little earlier.
    33633800661_dfacc61782_z.jpg

    Adde some support spacers mid way on the arm to keep it from being crushed with outside pressure.
    33721911806_1398b11d93_z.jpg

    This feels like anatomy class. The arm is glued at the top. It was tricky to work out the sequence of glueing the seams. Started with adding the 4" at the elbow, then glued the arm to the wrist disc. Then closed up the under seam.
    33606279712_fccf6ec6f8_z.jpg

    Now it's already looking like an arm.
    33762972725_4439b4aafb_z.jpg

    Hung the arm on the skeleton.
    32919725434_f9df0f9ac9_z.jpg

    Closing up the second one, forgot to do the 4" first, so that was trickier.
    33378273390_f0c7a2dee8_z.jpg

    Two forearms done. You can see the 2mm added pieces to the top half. Also I heat sealed the first arm all at once which taught me, DON'T put a heat gun on an arm that is made of PVC! My pvc coupler started to melt. Fortunately I caught it before damaging the joint.
    32949958013_4804ed05ce_z.jpg

    Added stops to the knee joints. No chicken legs for K-2SO.
    32949957603_0bb98884d5_z.jpg

    Feet are done.
    33633797661_2696e2337b_z.jpg

    Starting to work on the finger covers.
    33762971825_64aa46f583_z.jpg

    Got some 123 Blocks after watching chinbeard talk about them on youtube. Have used them a ton. Here I'm holding down pieces of 2mm foam so I can add score marks. Each finger will be wrapped around with the foam in this superman shield shape. I can trim it down to each knuckles length.
    32919724164_0371a570f5_z.jpg

    Speaking of chinbeard I got to catch his Q/A stream on Thursday (3/30) Asked him a question about budgeting time on foam projects, and was able to share this build blog. I hope he later had a chance to read through it. I've been watching a lot of twitch while working on K2 and am even prepping for some more over the next two weeks.
    33606277652_682d37b005_z.jpg

    Yes you heard right. K-2SO is not done. I came up a little short for my 4/1 deadline. I was disappointed I couldn't bring him to Wondercon this year, but he will make it for sure in 2018. But I'm still pushing through for my second deadline of 4/15. The So Cal RPF meetup! K-2SO and I will be there!
    I've entered all of my remaining components into a master list in todoist. Only 67 left!

    15 days until the RPF meeup

    33378281840_e887af1142_z.jpg

    32949970893_6b87a60d09_z.jpg

    33721917266_f2cc1c4e6b_z.jpg

    33378281030_0789eab842_z.jpg

    32919728004_7b002861fb_z.jpg

    33606281152_69418b6920_z.jpg

    32949962433_ba52b04e5f_z.jpg

    33721912646_c607914017_z.jpg

    33762974115_fdb8bfa89c_z.jpg

    33633800711_84b4529530_z.jpg

    33606279062_446b460dde_z.jpg

    33606280282_4f9865e840_z.jpg

    33762978485_baa6111be3_z.jpg

    33633802861_dab1e6bf36_z.jpg

    33633802331_072776c31b_z.jpg

    32919730744_a5c181585a_z.jpg

    32949966413_337fc8ecc3_z.jpg

    32949966513_072d498770_z.jpg

    33721914736_def6061329_z.jpg

    32949968573_64bdcd22c4_z.jpg

    32919727094_3df8a8f5ab_z.jpg

    32949961653_a84b5d211a_z.jpg

    33633800661_dfacc61782_z.jpg

    33721911806_1398b11d93_z.jpg

    33606279712_fccf6ec6f8_z.jpg

    33762972725_4439b4aafb_z.jpg

    32919725434_f9df0f9ac9_z.jpg

    33378273390_f0c7a2dee8_z.jpg

    32949958013_4804ed05ce_z.jpg

    32949957603_0bb98884d5_z.jpg

    33633797661_2696e2337b_z.jpg

    33762971825_64aa46f583_z.jpg

    32919724164_0371a570f5_z.jpg

    33606277652_682d37b005_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  16. karmajay

    karmajay Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    Great job!
     
  17. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Last two nights have been working on the finger covers. I've found a nice schedule for my evenings after work, time with family, dinner and some youtube. Followed by working on K2 between 9-12.

    I took the scored sheets and cut them to length for each finger.
    33445891180_1d8f2a26cd_z.jpg

    Using my 123 blocks to support the arm. I discovered I need to be careful where I put pressure on the foam as it can still bend or dent. I'll need to work out some sort of jig or rig I can transport the pieces in. Also for storage so it's not damaged over long periods of time.
    33701440361_d49121b675_z.jpg

    Skinned the thumb and pointer finger.
    33830679135_b50cd46414_z.jpg

    After the thumb is done I closed up the inside edge.
    33445890220_a4060d6020_z.jpg

    Right hand all skinned except for the finger tips.
    33701438041_96788cc9db_z.jpg

    Th palm of the right hand. I'll spray paint black the spaces between the covers at the joints.
    33701438031_6a39f914fb_z.jpg

    The next night I started on the left hand. Cut out all 15 pieces at once then stuck it all together.
    33674525532_b3ed6eecde_z.jpg

    Most of the steps of this build are building one side, which takes a while to figure out. Then mirroring it on the other side, which goes much faster.
    33674525592_772d7e3b4c_z.jpg

    I traced an extra cover strip that was glued in the shape of the finger covers. It had this guitar pick look. I trimmed out 11 or so pieces for gluing over the fingertips.
    33830678135_9f5ac7172d_z.jpg

    Lots of glue to the fingertips and the fingertip covers.
    33445889740_c86e2d54ef_z.jpg

    The fingertips are holding on nicely. When they are dry I'll trim off any excess around the edges with my sheers.
    33701437971_44b87ce1b8_z.jpg

    Working 2-3 hours every night is giving me good progress but not killing me like my 9p-3a building marathons were. With the hands done I'll start work on the biceps and the shoulder bells tomorrow. I need to get cracking on the legs by Thursday. It's crazy how I felt I could finish all of this last week. Working steadily every night shows me how much work there is to do. 66 items on my todo list with 12 days left.

    33445891180_1d8f2a26cd_z.jpg

    33701440361_d49121b675_z.jpg

    33830679135_b50cd46414_z.jpg

    33445890220_a4060d6020_z.jpg

    33701438041_96788cc9db_z.jpg

    33701438031_6a39f914fb_z.jpg

    33674525532_b3ed6eecde_z.jpg

    33674525592_772d7e3b4c_z.jpg

    33830678135_9f5ac7172d_z.jpg

    33445889740_c86e2d54ef_z.jpg

    33701437971_44b87ce1b8_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  18. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    I didn't get any more work done on K2 tonight but I did find 3 other cosplayers building K-2SO puppets and suits on Instagram! That seriously made my day.

    @harteattackcosplay is building his for C2E2 in only a few weeks. I know how that feels.
    33695193622_6e251efc7f.jpg

    @the_cosplay_guys have a 3D printed head like mine and are going for a suit type approach.
    33695194032_66807e84cf.jpg

    @imperial_rook has their K2 already walking! I can't tell if they are shorter or if their K2 is just very very tall.
    33695194252_10c75be3af.jpg

    I love how we all have approached this project differently. How awesome would it be to all meet up once our droids are complete! Keep on building my new K2 friends.

    66 items on my todo list with 11 days left.

    33695193622_6e251efc7f.jpg

    33695194032_66807e84cf.jpg

    33695194252_10c75be3af.jpg
     
    Last edited by a moderator: Nov 8, 2018
  19. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Evenings have been booked the last few nights so I was finally able to make more progress this weekend.
    Friday I started on a side project of sorts. A Death Star Plans Cassette prop for K2 to hold. I didn't need anything 100% accurate and there are much nicer models you can get on the RPF site. But I wanted one that was made of foam and light enough for my droid to hold.

    33770480702_501c3d544d_c.jpg

    Worked out the rough dimensions.
    33886289896_13c7790cfe_c.jpg

    I'll use some leftover PVC pieces for the static sinks on the side.
    33114770823_ff19a9d8c3_c.jpg

    Trimmed out the front discs.
    33797797331_b87dcc08e5_c.jpg

    I'm going to make two copies so I doubled everything. Why make one when you can make two.
    33797797411_b3517ac196_c.jpg

    All of the front and back discs cut and ready.
    33797796941_dfd68991b9_c.jpg

    Template for the two sides.
    33114770523_29470ffb99_c.jpg

    Getting position dialed in.
    33084269384_a6e9b57e48_c.jpg

    I cut the pvc in half for the side sinks.
    33797796521_d29fe85fa7_c.jpg

    Trimmed a lot of 5/8" strips for the side pieces and inner support.
    33770479322_1ccf587a28_c.jpg

    Unglued placement of the side walls.
    33084269054_e2009accac_c.jpg

    With the top cover and with the top cover removed.
    33114769893_46c8acda37_c.jpg

    I'll also add the pipes in the handle and glue some old ram to the bottom.
    33797795521_c3f9ed6939_c.jpg

    A discarded lid served as the plastic pieces.
    33084267774_eef8dbd2a7_c.jpg

    Glued down the outer wall first.
    33797794831_b3702b92c5_c.jpg

    Only glue on the bottom and inner faces of the outer wall.
    33797794791_542c375465_c.jpg

    Painted all the discs with my primer gray. Did detail work on the front pieces.
    33114768443_c25dbebfc0_c.jpg

    Tried to only apply glue where needed on the back.
    33927877315_d7bc556f5c_c.jpg

    Back discs in place.
    33114768163_1244f44397_c.jpg

    Super glued down the plastic to be sandwiched below the top piece.
    33542575980_6e847c4a1e_c.jpg

    Finished front.
    33927877055_803d19e484_c.jpg

    Finished back.
    33797793171_5b35d324ac_c.jpg

    I also picked up a little more PVC to make my head stand. This would also help with assembling the pieces. When K2 is in storage the head will stay inside with me on this stand. Made out of 1-1/4" pvc pieces.
    33084265484_e99959069c_c.jpg

    Primer coat.
    33927875945_ea4a70b912_c.jpg

    Same black as the rest of K2. Added some leftover bumpers that I tried to use as joint stops.
    33114764893_89b6fe9cc2_c.jpg

    With the neck piece in its socket.
    33927874825_d9857c56d9_c.jpg

    Today was all about the head. I sanded down the bondo to a smoother texture over the whole head.
    33797795411_9e73369b05_c.jpg

    Added a new coat of primer. I wasn't 100% satisfied but happy enough to move forward.
    33114769173_0fcfdd9b53_c.jpg

    This is actually with the black paint but the color balance is all off. It looks blacker than this image appears.
    33084265264_e6d65d8f80_c.jpg

    Started adding weathering details as I went with silver sharpies.
    33797792851_c5ed620c10_c.jpg

    Glue ready for the neck ring.
    33114766003_55940a1e9b_c.jpg

    While contact cement was becoming tacky I installed the eyes.
    33542574050_7933f0e7bf_c.jpg

    Glued down a strip of foam to be the new neck ring.
    33114764993_606d9dfd68_c.jpg

    Prepping the camera for installation.
    33084262624_849c8f9188_c.jpg

    POV camera glued with a small wedge behind it. If I need to I can remove that piece to look ahead more.
    33797789981_01b8878678_c.jpg

    Painted, weathered and glued together.
    33927874805_6d643f0c6e_c.jpg

    My plan is to install a shelf inside the head with REM (Rare Earth Magnets) to connect to the tripod head. I need them strong enough to hold the head on but not too strong to rip the mount out. Keeping 2-3 layers of 8mm foam in between them gives the right pull force.
    33084262074_b8d39fc7c5_c.jpg

    Marking the polarity side. Glued foam around the edges.
    33114764403_98d3521c69_c.jpg

    Layered with tape.
    33114761993_41e5dcce12_c.jpg

    Did a test of the neck detail with a little ring of foam. Will detail the whole neck stalk.
    33542571580_c06f74a66f_c.jpg

    Confirming REM polarity before installation.
    33084258584_bbffe4e513_c.jpg

    This part took a long time. I reshaped the shelf to be the hight I wanted it and reenforced it to hold the REM. It took a while to find the exact place to glue the shelf that put the pan/tilt head where I wanted it.
    33927873065_2be67ffa8b_c.jpg

    Added some super glue an tape to permanently install the pan/tilt head to the neck stalk. This can be done as the neck can be supported by the stand.
    33114761623_0255d87358_c.jpg

    Attached the POV camera battery to the pan/tilt. This way it's weight won't be on the tilt head.
    33797786991_58b8dfb619_c.jpg

    Glued in.
    33114762223_f7385bc06c_c.jpg

    End of a great day. Letting all of the contact cement cure before attempting to join the REM. Might need to fine tune the placement of the magnets etc. Hope to still be able to pan as well as tilt the head. Not a lot of clearance.
    33084259424_c671118d00_c.jpg
    Nocked off almost all of the head category tasks today. Also finished the DS plans cassette. Tomorrow night i'll start fabing the legs and try to knock those out.

    Also know that I'll be brining K-2SO to the SoCal RPF party next Saturday 4/15. I hope to have him finished by then, but he'll be there in whatever state he is in.


    58 items on my todo list with 6 days left.

    33770480702_501c3d544d_c.jpg

    33886289896_13c7790cfe_c.jpg

    33114770823_ff19a9d8c3_c.jpg

    33797797331_b87dcc08e5_c.jpg

    33797797411_b3517ac196_c.jpg

    33797796941_dfd68991b9_c.jpg

    33114770523_29470ffb99_c.jpg

    33084269384_a6e9b57e48_c.jpg

    33797796521_d29fe85fa7_c.jpg

    33770479322_1ccf587a28_c.jpg

    33084269054_e2009accac_c.jpg

    33114769893_46c8acda37_c.jpg

    33797795521_c3f9ed6939_c.jpg

    33084267774_eef8dbd2a7_c.jpg

    33797794831_b3702b92c5_c.jpg

    33797794791_542c375465_c.jpg

    33114768443_c25dbebfc0_c.jpg

    33927877315_d7bc556f5c_c.jpg

    33114768163_1244f44397_c.jpg

    33542575980_6e847c4a1e_c.jpg

    33927877055_803d19e484_c.jpg

    33797793171_5b35d324ac_c.jpg

    33084265484_e99959069c_c.jpg

    33927875945_ea4a70b912_c.jpg

    33114764893_89b6fe9cc2_c.jpg

    33927874825_d9857c56d9_c.jpg

    33797795411_9e73369b05_c.jpg

    33114769173_0fcfdd9b53_c.jpg

    33084265264_e6d65d8f80_c.jpg

    33797792851_c5ed620c10_c.jpg

    33114766003_55940a1e9b_c.jpg

    33542574050_7933f0e7bf_c.jpg

    33114764993_606d9dfd68_c.jpg

    33084262624_849c8f9188_c.jpg

    33797789981_01b8878678_c.jpg

    33927874805_6d643f0c6e_c.jpg

    33084262074_b8d39fc7c5_c.jpg

    33114764403_98d3521c69_c.jpg

    33114761993_41e5dcce12_c.jpg

    33542571580_c06f74a66f_c.jpg

    33084258584_bbffe4e513_c.jpg

    33927873065_2be67ffa8b_c.jpg

    33114761623_0255d87358_c.jpg

    33797786991_58b8dfb619_c.jpg

    33114762223_f7385bc06c_c.jpg

    33084259424_c671118d00_c.jpg
     
    Last edited by a moderator: Nov 8, 2018
  20. MooCriket

    MooCriket Master Member

    Trophy Points:
    3,366
    Such a great build. Enjoying every update:thumbsup
     
    DrscifiProps likes this.
  21. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    After 12 hours or so I believed the glue had set for the connecting platform in the head. It "snapped" perfectly onto the pan/tilt and aligned with the magnets. Just enough pull force to hold it in place but still removable.
    [​IMG]

    His head is getting full of wires. Beneath the blue tape is the switch for the eye LEDs.
    33939441245_9a8aeb3440_z.jpg

    I discovered that the head wouldn't tilt up. There was too much weight in the front. Solution, place my heavy 123 block in the back of the head as a counterweight. This worked great and moved the center of gravity over the pan/tilt.
    33554424530_74d1b9dc73_z.jpg

    Securing the 123 block. I kept all of the batteries in the head now to use their weight for balance.
    33554424870_7b571f00c5_z.jpg

    Fired up the POV camera for the first time since sanding/painting and it survived! The field of view is mostly clear with only a little bit of the left tusk showing in the corner.
    33782102582_36d11da958_z.jpg

    Really happy with how the weathering is coming along. Here you can see the POV camera, but most people probably won't catch it.
    33898578836_96f5eed53b_z.jpg

    His eyes look great even when they are off.
    33809373111_075485f481_z.jpg

    Made a foam filled box for transporting his head. I don't want to leave it on the pan/tilt when not powered so I don't accidentally damage the servos. 33939437885_74448e9c67_z.jpg

    Box head.
    33898578666_50d3fe7c81_z.jpg

    I am so happy the magnets work as intended. He can pan/tilt, it's a slow movement but better than a static neck.
    33554442280_69fc54c3a0_o.gif

    57 items on my todo list with 6 days left.

    33939441245_9a8aeb3440_z.jpg

    33554424530_74d1b9dc73_z.jpg

    33554424870_7b571f00c5_z.jpg

    33782102582_36d11da958_z.jpg

    33898578836_96f5eed53b_z.jpg

    33809373111_075485f481_z.jpg

    33939437885_74448e9c67_z.jpg

    33898578666_50d3fe7c81_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  22. Tumbler

    Tumbler Active Member

    Trophy Points:
    262
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    Very impressive! You must be exceedingly efficient during those wee hours of the morning. I too can only get stuff done at those times (kids, wife, life, etc) but I can't get near as much accomplished. Hard to believe you can squeeze in stuff like the data tapes prop. I would be loosing my mind just trying to get K2 done. Keep it up!
     
    DrscifiProps likes this.
  23. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    A few hours of work tonight. It's LEG DAY for K2. Not much room on my table but it worked.

    33840836201_2da3d08375_z.jpg

    Pulled out my foot top template to cut for the ankle.
    33127104434_bf641a4340_z.jpg

    Thats why templates are good, you can reuse them and not reinvent everything.
    33813016122_6998aa5205_z.jpg

    The two joining pieces. Ready for the puck rings.
    33585795630_dccfbee1bf_z.jpg

    Went together just like the elbow. Glued in two 2cm strips in the middle to close up that space.I'll replicate this technique on the elbows tomorrow.
    33840835291_4c0b91ab60_z.jpg

    Sketched out the knee joint plates.
    33929629296_4a911c8d19_z.jpg

    Found the center of these 12cm x 12cm pieces.
    33840835521_f149a6d1c7_z.jpg

    Ready to be glued onto the leg.
    33157766483_b972eea578_z.jpg

    Again I love how the angles come together on this build. The pieces fit great and don't smash into each-other with the stops in place.
    33929629336_1fdf8d1805_z.jpg

    Nice big knee joint.
    33127100594_80903bcf63_z.jpg

    I also streamed on http://twitch.tv/drscifi for a few hours tonight. I'll try to stream around 10p Pacific the next few nights.
    33813060722_5277cd37a5_z.jpg

    For the front of the knee I hit a problem. The pvc spider joint wouldn't let me use the same technique as the ankle and elbow as this center strip would not pass by the pipe connector area. So I glued a 4.5cm strip down to one puck but a few cm in from the outer edge.
    33929633656_e020eb3894_z.jpg

    Then the next strip on the other side was against the outer edge. Since the knee locks straight and only bends one way this works.
    33970881385_02cd3c012c_z.jpg

    When the knee is bent there is a small gap but a piece of foam is on the inside.
    33127105574_7c39804baa_z.jpg

    The back of the knees aren't great. I may try to replicate the front overlap. But this part gets squished a lot when the joint bends. I think some black paint will help hide most of this mess.
    33813020602_f91dbd25e3_z.jpg

    He looks super spindly without his outer skin on the legs.
    33840839771_278148ff22_z.jpg

    Right leg joints are done. The left should follow quickly as the design portion is already done. The outer skin will be 18" long and go from a 3" circle at the foot to a 4" circle at the knee.
    33157767123_17efe0cff6_z.jpg

    If I can finish the legs tomorrow and perhaps the arms then only the torso will be left. About 17 hours left scheduled to work on this before Saturday.
    I also realized I had a sublist of items for my supply backpack that I didn't need to count as steps. So I'm down to:
    48 items on my todo list with 4 days left.

    33840836201_2da3d08375_z.jpg

    33127104434_bf641a4340_z.jpg

    33813016122_6998aa5205_z.jpg

    33585795630_dccfbee1bf_z.jpg

    33840835291_4c0b91ab60_z.jpg

    33929629296_4a911c8d19_z.jpg

    33840835521_f149a6d1c7_z.jpg

    33157766483_b972eea578_z.jpg

    33929629336_1fdf8d1805_z.jpg

    33127100594_80903bcf63_z.jpg

    33813060722_5277cd37a5_z.jpg

    33929633656_e020eb3894_z.jpg

    33970881385_02cd3c012c_z.jpg

    33127105574_7c39804baa_z.jpg

    33813020602_f91dbd25e3_z.jpg

    33840839771_278148ff22_z.jpg

    33157767123_17efe0cff6_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  24. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    Came home for lunch today and finished the ankle and knee joints for the left leg. Tonight I did another twitch stream while I worked on the lower legs.

    Came up with the angles for the lower lower leg. It's very angular.
    33990288465_deca0002f7_z.jpg

    Cut out some mid supports to hold the top of the lower lower leg.
    33832757462_4245b03801_z.jpg

    Glued the support in place 10" from the ankle.
    33177371973_5f673b3d5f_z.jpg

    Worked out the angles. 1.75" edges on the front and side with a 2.25" piece on the back.
    33860468971_a1e2176793_z.jpg

    Almost forgot to make 2, mirrored of course.
    33832757832_2908c51d7e_z.jpg

    Scored to bend easier.
    33948669696_93801fccf6_z.jpg

    Waiting for the glue to tack.
    33832756752_e5937f0aae_z.jpg

    One lower lower leg done. Working on the second.
    33832757062_67b1da2b2d_z.jpg

    Both lower lower legs finished.
    33177374073_22865fc7bc_z.jpg

    Added a 4" circle to mate the lower leg upper piece to.
    33832757952_f22e1cba81_z.jpg

    Glued it to the pipe and the knee plate.
    33948671176_5196b1af1b_z.jpg

    You can see the curved lower leg upper cover drying.
    33990290075_84df68b035_z.jpg

    The piece of foam wraps around the 4" circle. First I center it, then tack it to the other glue spots working around to close the seam in the back.
    33832759232_c9163839ec_z.jpg

    The back seam is pretty strong. The bottom edge is glued to the lower lower leg piece.
    33860470421_de1b9088b3_z.jpg

    Both lower legs are done.
    33832758552_e3491e8c80_z.jpg

    More skin concepts coming together. I love this stage of the project where things are really coming together.
    33832758842_2cd91d058a_z.jpg

    Tomorrow will be the upper legs and perhaps starting on the torso. I'll try to finish the biceps too.
    33990289805_4f755e3cf4_z.jpg

    Added a cover of 2mm foam to the pan/tilt head. This covers the degree marks.
    33985547215_dd8bd879ec_z.jpg

    Opened up my second can of barge contact cement. Went through the first one. Glad I got 2.
    33832759642_1759ec161a_z.jpg
    We'll see how much I have done by the RPF party on Saturday. I don't have a lot of time. Perhaps he won't be weathered, but at least I want the major components together.

    46 items on my todo list with 3 days left.

    33990288465_deca0002f7_z.jpg

    33832757462_4245b03801_z.jpg

    33177371973_5f673b3d5f_z.jpg

    33860468971_a1e2176793_z.jpg

    33832757832_2908c51d7e_z.jpg

    33948669696_93801fccf6_z.jpg

    33832756752_e5937f0aae_z.jpg

    33832757062_67b1da2b2d_z.jpg

    33177374073_22865fc7bc_z.jpg

    33832757952_f22e1cba81_z.jpg

    33948671176_5196b1af1b_z.jpg

    33990290075_84df68b035_z.jpg

    33832759232_c9163839ec_z.jpg

    33860470421_de1b9088b3_z.jpg

    33832758552_e3491e8c80_z.jpg

    33832758842_2cd91d058a_z.jpg

    33990289805_4f755e3cf4_z.jpg

    33985547215_dd8bd879ec_z.jpg

    33832759642_1759ec161a_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
    NathansPROPS, cjchiu, kman and 2 others like this.
  25. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    K-2SO took some baby steps today. I'm very glad that I did this as it changed some of the design directions I was going. His head is very heavy and very far away from me. He is building up weight which is a small concern. Also I'm glad that I can lock the knees to have him support his own weight when I need to take a break. I feel like i'm working from the outside in, at least in the black vs white parts of him.
    [​IMG]

    So while taking a test walk the left puppet paddle snapped. The twisting force I put on it was too much for the popler wood.
    33165645384_4124ae2b0e_o.gif

    Cracked down the grain line. But didn't damage the hardware at all.
    33196388513_aca29b5621_z.jpg

    A quick trip to Home Depot and I had a reenforcing bracket. Yes I took my arm to HD to make sure the bracket fit what I needed.
    33196386093_de00ea52ac_z.jpg

    Screwed down the bracket over the crack.
    33623493910_a77199c066_z.jpg

    Added one to both sides for strength.
    33623492160_6a808ee894_z.jpg

    I also shortened one of the connecting pipes on the top half of the harness. This changes the angle to help keep K2 vertical.
    34009171545_a382c3ecd6_z.jpg

    I also put screws in at all of the junctions as the weight of K2 was pulling the pipe apart.
    33623493400_3a8c28943e_z.jpg

    I swapped out the coupler spider joint for a permanent 45* angle piece. The weight was just too much on the adjustable joint and it was getting close to failing.
    33879514311_fd46505955_z.jpg

    I also added a 45 degree to the setup stand.
    33851496162_31fe09eb31_z.jpg

    Today was fabricating the elbow skirt sleeve rings.
    34009170275_f5a63c3340_z.jpg

    I used my paperclip compass trick to draw 5" and 7.5" circles.
    34009169385_4f7a301424_z.jpg

    Ready to be cut out.
    33196384763_3ea386e223_z.jpg

    The compass trick in action. Just anchor it with a pen on one end and bend the paperclip to the desired lenght.
    34009175655_2388a3ea3d_z.jpg

    The large ring will slip onto the shoulder 1" pvc pipe. The small ring with a notch will be attached to the arm slip-ring and have magnets around its perimeter. The single ring will have magnets and be stapled to one end of the shoulder skirt.
    33165490354_bbbd64a09e_z.jpg

    Cutting out some of the wood to save weight.
    33967693496_34ee10c0ee_z.jpg

    The shoulder plate which will have magnets.
    33623498710_5db5ed8414_z.jpg

    The ring will have magnets that line up with the shoulder plate. Allowing the skirt sleeve to be connected and hide the shoulder pvc.
    34009175025_644c65bdb6_z.jpg

    All cut out.
    33623498470_2975136045_z.jpg

    Trying some magnet placements. I have enough to add 5 per sleeve ring.
    33623494530_e4a89011df_z.jpg

    The magnets are about 2/3rds the thickness of the board. I'll counter sink the magnets into the board.
    34009171255_1116a03090_z.jpg

    A little bit of progress tonight but having that walking test in the evening was very important. I'll finish the arm biceps tomorrow and start sewing the shoulder skirts and prepping the main torso foam.

    43 items on my todo list with 2 days left until the So Cal RPF party.

    33165645384_4124ae2b0e_o.gif

    33196388513_aca29b5621_z.jpg

    33196386093_de00ea52ac_z.jpg

    33623493910_a77199c066_z.jpg

    33623492160_6a808ee894_z.jpg

    34009171545_a382c3ecd6_z.jpg

    33623493400_3a8c28943e_z.jpg

    33879514311_fd46505955_z.jpg

    33851496162_31fe09eb31_z.jpg

    34009170275_f5a63c3340_z.jpg

    34009169385_4f7a301424_z.jpg

    33196384763_3ea386e223_z.jpg

    34009175655_2388a3ea3d_z.jpg

    33165490354_bbbd64a09e_z.jpg

    33967693496_34ee10c0ee_z.jpg

    33623498710_5db5ed8414_z.jpg

    34009175025_644c65bdb6_z.jpg

    33623498470_2975136045_z.jpg

    33623494530_e4a89011df_z.jpg

    34009171255_1116a03090_z.jpg
     
    Last edited by a moderator: Nov 8, 2018
  26. andymcleary

    andymcleary New Member

    Trophy Points:
    3
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    Amazing work, really excited to see the finished result.
     
  27. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Been building the past two days in prep for the SoCal RPF party.

    Test fitted the sleeve large circles.
    [​IMG]

    Here's how the small horseshoes go. The thick one is attached to the shoulder joint. The thin one will be on the end of the sleeve.
    [​IMG]

    Spacing magnets.
    [​IMG]

    Drill bit wasn't large enough for the magnets to had to make the holes bigger. Used a countersink bit.
    [​IMG]

    Secured the shoulder horseshoe.
    [​IMG]

    Sewing time!
    [​IMG]

    Prepped the sleeve cone.
    [​IMG]

    Sewed the edge together and turned it inside out.
    [​IMG]

    Stapled trimmed 1/2" elastic to the thin horseshoe.
    [​IMG]

    Stapled the other end to the large wheel.
    [​IMG]

    Both sleeves in place. I ended up adding binder clips to hold the two horseshoes together. All of that will be hidden under the shoulder foam.
    [​IMG]

    TORSO TIME! The RPF meetup is tomorrow and I can't let K2 go without something on his middle. I did the first steps on the torso between 9p and 3a. First I trimmed a mini torso to see how the foam would react trimming and bending it.
    [​IMG]

    Made a 6" ring for the neck hole for tracing.
    [​IMG]

    Started with the front panel.
    [​IMG]

    Scored and heat traced the lines.
    [​IMG]

    Time for the real thing. This step has scared me the most. So many curves and eyeballing it.
    [​IMG]

    I start by marking the center point on a whole roll of foam. 2' x 5'.
    [​IMG]

    Situate the front panel but not too low.
    [​IMG]

    Trim out the neck hole in a circle, then move half the circle at an angle to make it a circle after the wedge cut in the back is made. Wedge cut the front panel.
    [​IMG]

    Test fit over body.
    [​IMG]

    Back seam isn't cut yet, just holding it all in place.
    [​IMG]

    Trimmed back seam and taped it temp in place.
    [​IMG]

    Trimmed one arm hole then used the foam cutout to mirror on other side.
    [​IMG]

    Prepping the cog and bars panel support.
    [​IMG]

    Fitting the frame for the cog and bars.
    [​IMG]

    Made up some filler shapes for mounting the torso onto.
    [​IMG]

    Attached and braced. This will need a lot more bracing but will work temporarily.
    [​IMG]

    Made a pocket for the ipad.
    [​IMG]

    Extended the side parts that go under the arms. Clamped them in place as I adjusted the two sides to match. Then cut the back flush and taped. Will glue once doing final assembly.
    [​IMG]

    He looks good with a torso.
    [​IMG]

    Prep for glueing the ipad mini pocket.
    [​IMG]

    Access panel behind the cog and bars panel.
    [​IMG]

    I'd like it to sit inside the panel but on top will do.
    [​IMG]

    Ready for tomorrow at the RPF meeup.
    [​IMG]

    I'm going to post all of my RPF pictures in the next post to keep this one shorter.
     
    NathansPROPS likes this.
  28. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Head Complete!

    It's here! The RPF SoCal meetup!

    Gingerly packed K-2SO into my car. Lots of sound triangle foam.
    33906984122_523b880582_c.jpg

    Brought my work table and got a great setup spot in the middle of the room.
    34063551605_3f9e5712d4_c.jpg

    I printed up sheets of my project notebook for the table and had my 501st cards and instagram information printed out. Everyone was very kind and admired K2. Met a lot of great makers, some Instagram followers and twitch streamers. Evil Ted Smith and I had a great chat about sealing foam. I also was honored to be interviewed by Norm from Tested.com Can't wait to see the video.
    33906984382_f33b95800e_c.jpg

    There were so many amazing creations. Here's the pod from one of my favorite films growing up "Explorers"
    33906984732_ebb035d23d_c.jpg

    The Tested.com ranchor.
    33251936773_dd59f3bd6e_c.jpg

    Movie cars.
    34023038736_a4aaaf02ab_c.jpg

    K2 greeting everyone.
    33221243674_32891b147a_c.jpg

    Indiana Jones and the Last Crusade.
    34023038546_ab000227c8_c.jpg

    Some Star Trek: The Next Generation props.
    33906985482_80fd79d954_c.jpg

    Installed and used the ipad mini with the head camera for the first time. It worked great.
    34063552135_fba0dfbdff_c.jpg

    Frank gave out an award this year and it went to this amazing rocket pack from Tomorrowland! Loved this piece.
    33251937573_6fe66a1e89_c.jpg

    Ghosbusters trap!
    33906985942_9cffd74542_c.jpg

    A lot of makers, builders and friends.
    33221244354_8f71269082_c.jpg

    Really need to finish his waist.
    33906986862_bd99e9bda0_c.jpg

    An amazing puppet vulture I got to try out. Also the gentlemen with the beard (I'm terrible with names) helped me suit up in K2 so thank you.
    33221244994_cb9ed69019_c.jpg

    Evil Teds Destiny inspired foam armor.
    33906987842_05a152b175_c.jpg

    Reynolds Advanced Materials, you hear that! No more normal materials for us.
    34023039486_50ccdaf2cd_c.jpg

    Flower puppet from MIB.
    33679133750_0eddbf379d_c.jpg

    Rocketeer helmet!
    33221245714_873222eebd_c.jpg

    Beautifully painted Star Lord props and jacket.
    34023040216_a3dcb54b0a_c.jpg

    A ton of Star Wars props.
    33251938943_036141f596_c.jpg

    Tie bomber cutaway.
    33906988532_8e7dffa1bf_c.jpg

    BB-8 head.
    33221247054_b9170c61b7_c.jpg

    Animatronic vulture.
    33221247254_b1ed293105_c.jpg

    Star Trek props
    34023041296_97f78febed_c.jpg

    Miranda class (probably the Reliant)
    33934204481_7373d28d94_c.jpg

    These intricate display pieces are commissioned 500 at a time by a wealthy client. Such a fun project!
    33906989912_7776ba2007_c.jpg

    3d printed pieces everywhere.
    34063585065_953bcd9158_c.jpg

    Puppet Fozzie and Gonzo.
    34023079786_07e6cdc514_c.jpg

    The infamous HIC (Han In Carbonite) fridge.
    33221295604_69f7b0d830_c.jpg

    Yo
    33251968723_16113ce4b4_c.jpg

    Panorama of the room.
    34023080126_414c42e83e_c.jpg

    More 3d printed pieces.
    33251986333_70da5e0009_c.jpg

    Awesome magic the gathering layer cards.
    33679178700_1d94c81832_c.jpg

    My little table with EP-1C the mouse droid.
    33679178730_041f1ea4f5_c.jpg

    K2 Selfie.
    34023102896_13e4c88278_c.jpg

    I won an Epsilon Pro kit from smooth-on in the raffle, Will go towards sealing all of K2's foam.
    34063606475_5aa3c3bbd1_c.jpg

    Event was live streamed on twitch. You can see K2 in the lower left corner.
    34023105136_4bc164e2b1_c.jpg

    There was a Robocop arcade so of course I had to play it. ED-209 beat me though. Robocop was one of the first costumes I ever made.
    34023104846_735e92f767_c.jpg

    At the end of the event Wall-E showed up.
    34023106576_f7f35dc651_c.jpg

    My mouse droid got to come out and play with the robots.
    33907023402_0e2255c36a_c.jpg

    I took K-2SO for his second walking test around the shop. As you can see from the look on everyone's faces it went great! His knee lost a stop screw so it doubled back a little but I can fix that. He held up very well and puppeted around the room.
    I had such an amazing day and met so many kind makers. Everyone was giving me compliments on K2 and saying they couldn't wait to see him finished. I try to be a humble guy and love sharing my build thought process, struggles, and designs. But I was beaming the whole time. Thank you, RPF community for your support for my project. I can't wait to see the Tested.com interview and follow some of the builds I saw today.
    34023282246_7d89cc9914_b.jpg

    PS. If anyone was there and has pictures of K2 or VIDEO of when I walked around I would love to see it. Post here or DM me please.

    K2 is about 73% complete. My new target deadline is the Rancho Cucamonga Star Wars day held at the Victoria Gardens library. May 27th.
    36 items on my todo list / 41 Days Left

    33906984122_523b880582_c.jpg

    34063551605_3f9e5712d4_c.jpg

    33906984382_f33b95800e_c.jpg

    33906984732_ebb035d23d_c.jpg

    33251936773_dd59f3bd6e_c.jpg

    34023038736_a4aaaf02ab_c.jpg

    33221243674_32891b147a_c.jpg

    34023038546_ab000227c8_c.jpg

    33906985482_80fd79d954_c.jpg

    34063552135_fba0dfbdff_c.jpg

    33251937573_6fe66a1e89_c.jpg

    33906985942_9cffd74542_c.jpg

    33221244354_8f71269082_c.jpg

    33906986862_bd99e9bda0_c.jpg

    33221244994_cb9ed69019_c.jpg

    33906987842_05a152b175_c.jpg

    34023039486_50ccdaf2cd_c.jpg

    33679133750_0eddbf379d_c.jpg

    33221245714_873222eebd_c.jpg

    34023040216_a3dcb54b0a_c.jpg

    33251938943_036141f596_c.jpg

    33906988532_8e7dffa1bf_c.jpg

    33221247054_b9170c61b7_c.jpg

    33221247254_b1ed293105_c.jpg

    34023041296_97f78febed_c.jpg

    33934204481_7373d28d94_c.jpg

    33906989912_7776ba2007_c.jpg

    34063585065_953bcd9158_c.jpg

    34023079786_07e6cdc514_c.jpg

    33221295604_69f7b0d830_c.jpg

    33251968723_16113ce4b4_c.jpg

    34023080126_414c42e83e_c.jpg

    33251986333_70da5e0009_c.jpg

    33679178700_1d94c81832_c.jpg

    33679178730_041f1ea4f5_c.jpg

    34023102896_13e4c88278_c.jpg

    34063606475_5aa3c3bbd1_c.jpg

    34023105136_4bc164e2b1_c.jpg

    34023104846_735e92f767_c.jpg

    34023106576_f7f35dc651_c.jpg

    33907023402_0e2255c36a_c.jpg

    34023282246_7d89cc9914_b.jpg
     
    Last edited by a moderator: Nov 8, 2018
  29. BlobVanDam

    BlobVanDam Sr Member

    Trophy Points:
    1,085
    Man, that looked like such a good day. K2 is looking great so far, even unfinished. It already captures his "character" very well.
     
    MooCriket and DrscifiProps like this.
  30. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Some walking footage from the RPF party.

    [​IMG]

    He held together pretty well, i'm still getting used to his motion.
     
  31. Tim Sayre

    Tim Sayre New Member

    Trophy Points:
    4
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    It was great to meet you and see K2-SO! That was an incredibly inspiring day and your build was one of my favorites. Always cool to see the ingenious ways people solve problems. Makes me feel like I might just be able to finish the rest of BB-8 one day.... time to finish recalibrating my 3D printer. Times wasting!


    Sent from my iPhone using Tapatalk
     
    DrscifiProps likes this.
  32. Stinkape

    Stinkape Active Member

    Trophy Points:
    341
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    AWESOME !! keep it up !!
     
    DrscifiProps likes this.
  33. MooCriket

    MooCriket Master Member

    Trophy Points:
    3,366
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Thanks for sharing , this is so cool!
     
  34. cckaiser2

    cckaiser2 Active Member RPF PREMIUM MEMBER

    Trophy Points:
    461
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Awesome event to display your talent! You've done such a great job of sharing your process from start to finish!


    Sent from my iPhone using Tapatalk
     
    DrscifiProps likes this.
  35. SofaKing01

    SofaKing01 Master Member

    Trophy Points:
    3,660
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Amazing!!!!
     
  36. WireFox

    WireFox Active Member

    Trophy Points:
    361
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Keep up the great work! :)
     
  37. BlobVanDam

    BlobVanDam Sr Member

    Trophy Points:
    1,085
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    https://www.youtube.com/watch?v=T7c5kFSEk3s

    Tested has just put up the video. Great interview, and great footage of the walking. Do you plan to do any sort of head movement? Seeing it moving, I feel like that would complete the illusion.
     
    cckaiser2 likes this.
  38. chefhawk

    chefhawk Well-Known Member

    Trophy Points:
    795
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Cracking work and great interview on Tested

    I look forward to see the final version
     
  39. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    The head will pan back and forth. Just needed to charge it up that day. Remote will be in my hand.
     
    cckaiser2 likes this.
  40. Engelnicht

    Engelnicht Well-Known Member

    Trophy Points:
    566
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Interview turned out great! Amazing job!
     
    cckaiser2 and DrscifiProps like this.
  41. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Here are some pictures of my cleaned up workspace.

    [​IMG]

    Ready to continue droidmaking.
    [​IMG]

    My shop light means I won't be in darkness anymore on twitch.
    [​IMG]

    Some decoration.
    [​IMG]

    The Tested RPF video has passed 100k views in 16 hours. Wow.
    [​IMG]

    I'm also adding a second camera to my twitch streams. No it won't be of the same image. ha!
    [​IMG]

    I wanted to thank everyone who's watched the Tested interview and shared so many kind words. I've actually had a good experience in the YouTube comments answering questions. The maker community continues to amaze.
    I plan on streaming some more K2 progress tomorrow night.

    -Darren
     
  42. veektohr

    veektohr Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,991
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    It's me, the bearded gentleman. Your K2 was a real show stopper man! I'll be your squire any day


    Sent from my iPhone using Tapatalk
     
    DrscifiProps likes this.
  43. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps


    Ha! I hoped the internet would provide a connection. I meant to say thank you as we were packing up but missed the chance. Social Media connections incoming.
     
    Engelnicht and veektohr like this.
  44. H0llyw00d

    H0llyw00d Sr Member

    Trophy Points:
    1,426
  45. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    Engelnicht likes this.
  46. DrscifiProps

    DrscifiProps Well-Known Member

    Trophy Points:
    511
    veektohr and Engelnicht like this.
  47. Mechanized2400

    Mechanized2400 Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,731
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Stellar work mate; loving this thread :thumbsup
     
    DrscifiProps likes this.
  48. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

    Trophy Points:
    3,376
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Thanks for sharing the pictures!

    p.s: I am soooo ready for a german RPF get together :thumbsup
     
    veektohr and Engelnicht like this.
  49. pmangels17

    pmangels17 New Member

    Trophy Points:
    3
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    Love the build and the interview on Tested! Any insight into where you got your files for 3D printing?
     
  50. cckaiser2

    cckaiser2 Active Member RPF PREMIUM MEMBER

    Trophy Points:
    461
    Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

    He got them off of thingverse.


    Sent from my iPhone using Tapatalk
     

Share This Page