ROGUE ONE K-2SO Puppet Build

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

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I was smarter this time and stacked the 4 edge pieces together to cut them at the same time.
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Each toe is made of a top, two sides and the bottom. I should be able to glue these all together in about an hour tomorrow.
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So the feet will be done tomorrow. I'll have the ankles done for sure and hopefully the leg templates complete.

Still 27 days left.
 
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Another night and more progress.
I glued together the cut seam for the ankle joint outer pucks. I also trimmed out the center core of the other 3 copies.

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Created an inlay for the mirror.
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This way it sits flush and is easier to mount the puck to the joint.
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The toes came along nicely. Glued the sides to the top first. Wrapping the edges around.
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Testing the fit.
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The under piece presses out on the walls so the overall shape is trapezoidal.
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Everything is flush on the bottom.
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Feet are 90% complete. Just need to trim the lace cover a little around the toe so it can bend some.
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I'll also glue the lace cover down and trim the back corners for some nice angles on the foot.
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Very happy with how this turned out, and it's not even painted and weathered yet!
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More progress tomorrow.
26 days left

-Darren
 
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Your progress is great, your work is outstanding, love the way it's coming together, can't wait to see the hands come together, keep up the great work
26 days left !!! :eek
you can do it :thumbsup
 
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Working on my calendar.
15 days left
Scheduled out my evenings and remaining weekends. I have roughly 65-71 hours left.
More progress pictures going up this weekend.
Legs are coming together and the head is being 3D printed.
I've also ordered everything I think I should need to finish except for the paint.

Let's do this!

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

Let's do this!

-Darren
good luck my friend looking forward to the updates
 
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Re-elect Mayor Goldie Wilson, progress is his middle name!

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

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The head has been printed! My friend Steven over at Inland Empire Armory printed my K-2SO head for me. I just supplied the filament and he took care of the rest. All while graciously allowing me to hound him for progress pictures every day.
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Head half with the support core.
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Deeper and taller.
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Only half a brain on this droid.
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Printing the wrap around lower head.
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All of the pieces coming together.
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A very loose test fit. Figuring out how this all goes together.
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All of the pieces. I ended up not needing the two core blocks from the center of the jaw. I'll also be modifying the under side to allow the pan/tilt head to operate.
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Taping everything together.
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It looks great. I have the mouth plate on backwards here but this gave me a feel for how the head will look. I'm planning on mounting my spy camera in the cheek area.
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Flipped around the mouth plate. Everything looks good and fits well together.
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I plopped the whole thing on top of the pan/tilt head to see if it could handle the weight. Was very happy it can. The pan/tilt head will be relocated inside the head but it can pan and tilt!
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Close up of the cheek area.
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I'm planning on attaching the camera battery here to the front of the pan/tilt. The cable should reach for the camera but not have the battery weight on the motor.
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I also plan to put the camera logic board here where I can see the display light out through one of K2's light up greeblies. I just need to be sure I can still turn it on/off.
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Cut away some of the internal structure so the pan/tilt head had more room. Panning isn't a problem, but with the pan/tilt inside the head I needed more space for it to tilt up and down.
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I temporarily placed the leftover chin core inside the head to get the pan/tilt placement.
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The pan/tilt sits just below this layer of the head.
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This means I need to cut away a lot of the lowest layer, the underside of the head.
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I'm keeping the front part which will have some of the chin glued to it. The rest will be discarded. I'll create a rim following where the piece was out of a strip of foam. Perhaps put some black cloth in.
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Covering the cut point with foam.
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Cut out K2's eyes from a milk jug. Still need to wire up the lights.
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My garage will not be hosting a care for the next week. This will save me setup time as I work on K2 every night.
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12 days!

Expect more updates here.

-Darren

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

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

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

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Ran to Home Depot during my lunch and picked up a few supplies. Grabbed filler primer and bondo putty for the 3D printed head. This will help smooth it out for painting and detailing.
I also purchased screw eyes for guiding the hand linkages, two wooden planks for the hand puppet plates, some latex gloves and PAINT!
Picked up my 2x Rustolium primer paint and the black high heat BBQ paint. I've seen others who paint K2 use this color and it has that flat metallic look I'm going for.
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I also want to make one of these Death Star data cassettes as a prop for K2. This isn't my build but an example of what I want to do. A little foam, some CD spindle pieces and wires and I'll have a nice prop for the tall guy.
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My back harness arrived. With so much of K2's weight being placed on my lower back, I don't want to hurt myself. So far the layers are building up. The back brace, then the chest harness, then the Imperial Officer tunic.
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Did a lot of design work on the puppet hand plates. As I always say, there's a point in every project where scale matters. I've reached that point. This was my first design, determining how far I'll be from K2's back and center line. I changed tactics once I realized that his elbow will be almost at my shoulder height. I need to be able to keep his arms at a neutral stance without bending my wrists too much.
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So I shifted to this design. The panels are closer to the elbow and connect at a 30*-40* degree angle. This lets his arms hang down at his sides without my bending my arms or wrists. But I can still pivot my wrist and make him reach up for higher objects etc. I still need to dial in the exact angle but it will be close to this. Screw eyes and the drip line hose will create the channels for the tendon lines. They will be long but should not loose grip due to the drip line sleeves.
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More work and hopefully some fabrication tomorrow night.
10 Days Left

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

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I found these tiny Traxxas wheel struts. They are tiny turnbuckles and perfect for this application. One side is adjustable up to 1/2 an inch. I can pop out the bearings and have a solid ring to tie the control line to.
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I also found some thin foam packaging at work that was being tossed out. I want to loop this into a cylinder and stuff the elastic tubes on the shoulders and hips for more rigidity.
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A full night in the garage to be sure.

9 Days left

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Very productive today. Spent about 8 hours on K2 tonight.

I'm modding a Nerf gun to use as his blaster, keeping it light.
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I removed the internal mechanisms, and the trigger. I'll later slice off the top arm and add a scope. This blaster is cool in that it has a detachable barrel. I'll keep that added part with the orange safety tip. But the rest will be black for closed area photo shoots.
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Started to template out the puppet plates.
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This was the trickiest angle to get right. I needed K2's arms to be in a natural position when I have my hands in a natural position. But also be able to fully extend them if I want to.
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Working on mounting the finger tendon guide tube to the puppet plate.
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Most of my work tonight was on the hands. I added some extra pipe to the core structure T joints. Drilled out the 4 finger holes and sanded them to the proper size with my dremel.
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A test fit of the finger material.
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I cut out all of the right hand finger pieces and wired up another finger. Only 4 more fingers to wire. These are turning out straighter and faster than my first attempts.
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Got the digital version of Rogue One on Amazon. So watched that in the background while working. Pausing frequently for more screen shots.
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Just look at this beautiful picture of K2's back!

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Loosely ran the tendon cord down one finger for testing. The elastic will also run down the inside with the whole thing capped with 2mm foam.
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Cut all of the 10 tendon guide tubes so they can stretch out and straighten before installation.
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Finished finger holes.
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I also extended the bicep piece. Top is old length, bottom is new.
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Can't wait to meet you K-2SO.
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8 Days Left

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