The Force Awakens Z6 Riot Control Baton

renegadecow

Active Member
Like just about everybody else, this new weapon greatly intrigued me and the moment I saw it function on the big screen, I was hooked. Not long after I was contacted by Jimmi who also wanted one and this was the final push for me to make it as I was on edge about making just one for myself as it needed quite a few molds to make. For reference, I'm relying heavily on the Figuarts action figure while scaled to the scene where it's sent spinning for the first time on screen. Material is primarily PVC as there are other people also wanting to duel with it. Unlike all of the builds prior, I'm not making the arms flip out by the push of the button on the handle. I'm more convinced that that button is for controlling the electric current on the prongs and after studying the scene from the movie it appears to me that all TR-8R does is jerk it in a back and forward motion. This leads me to believe that it's better to make it with an inertial lock: the baton is jerked back and the weight of the lock uncouples the axle. The axle is then powered by a weak spring, just enough to make them pop out and then when the user jerks the baton forward, it sends the arms flying forward like a side folding knife instead of the violent action of a spring assisted switch blade.

The main body is constructed from a single piece of PVC for rigidity. It's also extruded oval as the real thing isn't actual cylindrical.
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For simplicity, I'm not making the arms fold in automatically towards the body. Instead I'll be making a replaceable axle so it can be manually put in that configuration.
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The most complex part would be the rear extension of the body. It transitions from a round profile to an octagonal one which I've done by molding a separate piece that goes around it.
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More work on the handle (cutouts) which reveals the hole opposite the handle which I ended up not needing as the three parts are all anchored by the side screws. Will be filling up the hole with epoxy later and omit it in succeeding casts.
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If you hadn't at least put that caption there, I was going to call the test a complete failure. But since you did, I can safely say that it's coming along nicely!
 
I was considering a rising/falling hinge set-up.

Perhaps a tube inserted into another tube, that has a curved edge against it. As the first tube rotates (rotating an arm) it travels along the curve, giving us an upward (or in this case, outward) motion. Pop a spring into the centre and it'll self-close too, so a latching mechanism would be needed.

I'm not describing it very well, but look at rising hinges and you'll see what I mean. The challenge is in keeping the rotary motion, while facilitating the linear outward motion too. But considering we're only talking fractions of an inch, it shouldn't be too tough to do.
 
I get what you mean. The problem there is that the arms need to pop out sideways first to clear the main body before swivelling out. I've devized a way to do that having the axis of the arms as telescoping into each other, but would entail some serious amount of machining and more durable stuff than PVC.
 
If the arms are rotating against a curved axle (it's really difficult finding the right words to describe what I'm thinking!) they'd pop-outward on rotation. If the axle rotated freely, then caught the arms on the way round, it could lift them and then lift-rotate them too... I need to sketch out the idea really... >.<

It could be done with piping and angled cuts on the end. I need to visualise it and put it into a diagram, but I'm certain all of the motion can come from that simple rotation, without complex machining. The only barrier that comes to mind is friction.
 
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..Does this make sense?... :wacko

The axle arms for each side need not be joined, they could still be driven by the same spring-strap set-up, which gets around any need for telescoping, etc.

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...and you thought the diagrams couldn't get any worse! XD

- - - Updated - - -

...If you staggered the rotation and went for >180+ degrees on the unwind, you could force the arms out, then catch a secondary axle that rotates the whole assembly (I'm not even going to attempt to draw that!)... :lol

So, the first 90 degrees moves them outward via the (outer?) axle, which then catches the secondary axle (interior?) via a notch, or slit set-up... It then continues on for the 180 degree rotation to swing out the arms, once clear of the body... A spring between the two arm assemblies would act to pull them back together, forcing them to rotate back and close back against the body.
 
Lock worked a treat! It's similar in function to liner locks on folding knives. When the notch in the axle reaches past the lock, the lock springs up and holds it from rotating back. Will be disguising the unlock button as one of the red dot/LEDs on the body.
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Looks great so far! I went to Home Depot today to get some pieces to make one for my son (based on Caleb Kraft's build). If anyone knows where to get the oval pvc in the USA, please let me know. I bought some rounded rectangle rain gutter downspout, but I'm not satisfied with it.
 
Do you plan on selling them as kits or assembled once you complete this? I'd really like to build one, but I don't feel like I have the level of skill you do, so far, it looks amazing!
 
I'll be selling them locally, but for international sales the shipping cost will be high. Will have to at least cut the main body in two and mostly disassembled to fit in a smaller, more cost effective package.

On to updates, pretty much done with the front section. The end cap molded smoothly, surprisingly enough and ridges on the arms are pretty much straight forward. And with the arms now glued and screwed down into the axle it's strong enough for light sparring.
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Looks amazing, RC! I can't wait for mine! And you'll be making more than a couple of folks from my garrison happy. :)
 
Please do try to draw a diagram, sounds like a possibly good plan but i cant visuaize it. like are you talking about using two rising hinges with one inside of the other and the first just catches the second?
 
Had nothing to do while waiting for the spikey bits to cure (cast in PVC/epoxy combination) so I started work on the copies. Having been swinging around the prototype in front of a mirror longer than I care to admit, I found it a little too long so the copies will be corrected: less one inch up front and half an inch at the back.
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Had nothing to do while waiting for the spikey bits to cure (cast in PVC/epoxy combination) so I started work on the copies. Having been swinging around the prototype in front of a mirror longer than I care to admit, I found it a little too long so the copies will be corrected: less one inch up front and half an inch at the back.
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Oh, please tell me one of those is mine, ol' buddy, ol' pal! :lol LOL!

Yes, I was noticing the prototype seemed too long to effectively "spin", especially in the mobility-restricting TFA armor (damn you, gaskets!).

Personally, I would rather too short than too long. I know tonfas shouldn't extend more than an inch past the elbow at MOST, so maybe that's a good starting point. Will it be possible for someone who orders one from you to shorten it even more if necessary (perhaps by having it shipped with the endcaps unglued)?
 
With the main section cut in two for shipping, one could simply cut more material on one end before putting the two together and reposition the silver colored bands (likely to make these as strips of aluminum). But the arms are pretty much fixed in length unless you glue the ribs on yourself to line up with the repositioned bands on the body.
 
With the main section cut in two for shipping, one could simply cut more material on one end before putting the two together and reposition the silver colored bands (likely to make these as strips of aluminum). But the arms are pretty much fixed in length unless you glue the ribs on yourself to line up with the repositioned bands on the body.

I'd be okay with gluing those ribs in myself, as we discussed fyi =)

I am so excited for this project! I didn't have any love for this prop until I saw yours.
 
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