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.
Time for some primer filler on the 3d printed pieces.
Everything got a coat or two. It really helped smooth things out.
But i'll still need some bondo putty.... we'll get to that later :/
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!
Watching some twitch while I work. I've streamed some but no one seems to be watching while the world is asleep.
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.
Got pretty good with the bandsaw.
Storage, not drying.
Next piece to fabricate was the arm edges that touch the joints.
This is the elbow. Again the bandsaw makes quick work of the foam.
Test fit.
Glued in the two end shapes.
Cut some curved foam to add more glueable surface area.
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.
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.
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.
IMB_uDHjmL by
drscifi, on Flickr
Counter sunk the mirrors in the ankle and wrist pucks.
The ankle pucks.
All joint pucks are done.
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.
While wandering around Home Depot, as I tend to do. I came upon these nylon hose elbows.
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.
The whole thing illuminates and disperses the light evenly.
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.
With the right angle they sit flush on the support shelf inside the head.
And look AMAZING! Just what I wanted. K-2SO doesn't have Iron Giant glow eyes, he has irisis and pupils.
His eyes are more like rings, and actually shift as he looks around.
Wonderful.
In gif form.
I drilled out the holes on this little side chip.
It will let some of those extra eye LED's through.
Time for super glue.
Did some streaming.
It was so fun to put this puzzle together.
Everything fits. Trying out a place for the spy camera.
I'm going to moun the spy camera circuit board here so the power/status LED can be seen.
Might use this LED or might use the eye white ones. Which will probably wash this one out.
Temp holding the spy camera in place. Again, when the head is black you won't see the ribon at all.
Marking out a cut out to hold the ribbon when the two pieces are joined.
Trimming 3d Prints is interesting, you never know whats beneith the surface.
Perfect.
It sits flush.
Time for super glue.
The lip shelf was a great clamp spot while the glue set.
Two tusks
You can see how the filler primer really helps reduce or even eliminate the 3d print striations.
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.
Looking good.
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.
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.
Ugh, added some more filler primer to try to cover up the clay. Welcome to stone golumn K2.
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.
The components of the inner mount. It straddles the "V" groove inside the top of the head.
REM magnets will go on this plate, though I need to lower it some.
Thumbs! Time to finally get the inside of the hands complete so I can skin the arms in foam.
Working out the angle and placment of the thumb was tricky. Then mirroring it on the other side was even trickier.
It wiggles a little, but you gotta have thumbs.
The wired up hand.
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.
Yep, I'm Tony Stark.
Same work bench. Time to start skinning.
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.
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.
Scoring the top and bottom of the hands. Once I heat seal these they will open up some and look awesome!
Ready to glue, but it's 5am so time for sleep.
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.