ROGUE ONE K-2SO Puppet Build

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.


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:
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!
 
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:
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:
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.


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

Test fitted the sleeve large circles.


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.


Spacing magnets.


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


Secured the shoulder horseshoe.


Sewing time!


Prepped the sleeve cone.


Sewed the edge together and turned it inside out.


Stapled trimmed 1/2" elastic to the thin horseshoe.


Stapled the other end to the large wheel.


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.


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.


Made a 6" ring for the neck hole for tracing.


Started with the front panel.


Scored and heat traced the lines.


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


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


Situate the front panel but not too low.


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.


Test fit over body.


Back seam isn't cut yet, just holding it all in place.


Trimmed back seam and taped it temp in place.


Trimmed one arm hole then used the foam cutout to mirror on other side.


Prepping the cog and bars panel support.


Fitting the frame for the cog and bars.


Made up some filler shapes for mounting the torso onto.


Attached and braced. This will need a lot more bracing but will work temporarily.


Made a pocket for the ipad.


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.


He looks good with a torso.


Prep for glueing the ipad mini pocket.


Access panel behind the cog and bars panel.


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


Ready for tomorrow at the RPF meeup.


I'm going to post all of my RPF pictures in the next post to keep this one shorter.
 
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:
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
 
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
 
Re: ROGUE ONE K-2SO Puppet Build - Taking Steps

Cracking work and great interview on Tested

I look forward to see the final version
 
This thread is more than 5 years old.

Your message may be considered spam for the following reasons:

  1. This thread hasn't been active in some time. A new post in this thread might not contribute constructively to this discussion after so long.
If you wish to reply despite these issues, check the box below before replying.
Be aware that malicious compliance may result in more severe penalties.
Back
Top