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  1. DrscifiProps's Avatar
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    Jan 15, 2017, 11:29 PM - Re: ROGUE ONE K-2SO Puppet Build #51

    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.
  2. goldenhawk's Avatar
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    Jan 20, 2017, 10:12 PM - Re: ROGUE ONE K-2SO Puppet Build #52

    Awesome build. What PVC parts did you use to make the knee and elbow joints?
  3. DrscifiProps's Avatar
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    Jan 20, 2017, 10:16 PM - Re: ROGUE ONE K-2SO Puppet Build #53

    goldenhawk said: View Post
    Awesome build. What PVC parts did you use to make the knee and elbow joints?
    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.
  4. RPF Premium Member
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    Jan 20, 2017, 10:19 PM - Re: ROGUE ONE K-2SO Puppet Build #54

    How's the build coming along?


    Sent from my iPhone using Tapatalk
  5. DrscifiProps's Avatar
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    Jan 20, 2017, 10:35 PM - Re: ROGUE ONE K-2SO Puppet Build #55

    cckaiser2 said: View Post
    How's the build coming along?


    Sent from my iPhone using Tapatalk
    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/BPdW2V7D...aken-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
  6. DrscifiProps's Avatar
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    Jan 21, 2017, 12:10 AM - Re: ROGUE ONE K-2SO Puppet Build #56

    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 ass lines and some great puppeteering. I can't wait!
  7. Member Since
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    Jan 21, 2017, 1:20 AM - Re: ROGUE ONE K-2SO Puppet Build #57

    Following this. Great work!
  8. goldenhawk's Avatar
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    Jan 21, 2017, 12:56 PM - Re: ROGUE ONE K-2SO Puppet Build #58

    DrscifiProps said: View Post
    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 ankleso
    1x connection point


    Perhaps I should keep a parts list in the first post to help people out.
    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.
  9. Jan 21, 2017, 6:59 PM - Re: ROGUE ONE K-2SO Puppet Build #59

    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's Avatar
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    Jan 21, 2017, 7:33 PM - Re: ROGUE ONE K-2SO Puppet Build #60

    TheBlackPhantom said: View Post
    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!
    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. Jan 21, 2017, 7:56 PM - Re: ROGUE ONE K-2SO Puppet Build #61

    DrscifiProps said: View Post
    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.
    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's Avatar
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    Jan 24, 2017, 2:36 AM - Re: ROGUE ONE K-2SO Puppet Build #62

    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.




    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
  13. Stinkape's Avatar
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    Jan 24, 2017, 8:42 AM - Re: ROGUE ONE K-2SO Puppet Build #63

    Looking forward to your progress, great job !!!!
  14. DrscifiProps's Avatar
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    Jan 24, 2017, 9:45 PM - Re: ROGUE ONE K-2SO Puppet Build #64

    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's Avatar
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    Jan 25, 2017, 9:26 PM - Re: ROGUE ONE K-2SO Puppet Build #65

    I'm going to livestream working on K-2SO around 8:00p Pacific. https://www.twitch.tv/drscifi Tune in.
  16. goldenhawk's Avatar
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    Jan 28, 2017, 9:12 PM - Re: ROGUE ONE K-2SO Puppet Build #66

    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's Avatar
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    Feb 2, 2017, 1:14 AM - Re: ROGUE ONE K-2SO Puppet Build #67

    Time for another update! T-8 Saturdays until my April 1st self-imposed deadline

    A new exciting piece came today. A micro wifi camera for my POV system. Purchased from Amazon. https://www.amazon.com/gp/product/B0...?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.



    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.


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



    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.


    Measure twice, cut once.


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


    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.



    I coated the joining sides with barge contact cement.


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


    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.


    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.


    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.


    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.


    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.


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


    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.


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


    I'm also ordering a scalloped blade for my borrowed band saw.
    Click image for larger version. 

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    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
  18. DrscifiProps's Avatar
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    Feb 19, 2017, 3:19 PM - Re: ROGUE ONE K-2SO Puppet Build #68

    Streaming on Twitch now. Cutting with my new scalloped blade.
    https://www.twitch.tv/drscifi
  19. DrscifiProps's Avatar
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    Feb 20, 2017, 1:10 AM - Re: ROGUE ONE K-2SO Puppet Build #69

    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.


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


    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.



    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.



    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.


    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.



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


    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!


    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!


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


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


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


    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.



    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.


    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.


    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.


    Here's the elbow pice placed over the spider joint.


    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.



    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.


    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
  20. DrscifiProps's Avatar
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    Feb 25, 2017, 2:46 AM - Re: ROGUE ONE K-2SO Puppet Build #70

    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.



    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.


    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.


    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.



    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.


    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.



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


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


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


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


    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.


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


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


    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.


    1 finger down, 9 to go.


    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.


    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/BPYgDzGD...aken-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
  21. LeClubNerd's Avatar
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    Feb 25, 2017, 9:17 AM - Re: ROGUE ONE K-2SO Puppet Build #71

    Keep up the awesome work.
  22. DrscifiProps's Avatar
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    Feb 26, 2017, 1:20 AM - Re: ROGUE ONE K-2SO Puppet Build #72

    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.


    The Grommash finger edge.


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


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


    Finger digit layers.


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


    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.


    Plan A PVC pipe and Plan B PVC sheet.


    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
  23. Friendly flyer's Avatar
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    Feb 26, 2017, 6:28 AM - Re: ROGUE ONE K-2SO Puppet Build #73

    Cool! The linked finger seems promising!
  24. mmhnc's Avatar
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    Feb 26, 2017, 6:47 AM - Re: ROGUE ONE K-2SO Puppet Build #74

    I want this idea, it seems like it will look more accurate.
  25. cjchiu's Avatar
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    Feb 26, 2017, 7:50 AM - Re: ROGUE ONE K-2SO Puppet Build #75

    Wow. Impressive. Seems like fingers are really complicated no matter which direction you go.

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