ROGUE ONE K-2SO Puppet Build

Cut out the puppet plates while on my lunch break today. It's amazing how fast the work is when you use the right tool. Tried to start cutting these with my dremel last night and got nowhere. Jigsaw took 3 minutes.

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Also went by Home Depot on the way home. Got some bigger screw eyes for guiding the draining pipe. Also found some hinges and 3/4" pipe for the finger controls. I think I have everything I need to assemble tonight. We shall see.
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8 days left and doing great!

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Well I am definitely in con cosplay crunch mode. The last two nights i've worked from 9pm to 3am. Making great progress but feeling a little tired.
With the puppet plates cut out I marked where they would be slotted into the forearm. This narrow rectangle was cut out with my dremel.

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Held mostly by friction I ran a bead of hot glue along the edge and ran 3 screws through the PVC pipe to secure everything nice and tight. This joint would undergo a lot of stress and needed to hold fast.
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I mocked up the position before final glueing.
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Ready to paint.
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Primer coat.
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Flat black coat. I painted at this step because the wood would be under a lot of hardware. I'll touch the hardware up with more black paint but this way no wood grain will ever show through.
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Ready for hardware.
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I finished the rest of the fingers for the right hand. And did some elastic and tendon tests.
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I ended up not re-doing any of the connection bars but instead ran the tendons and elastic on the outside of the finger.
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Starting plans for the finger controls. Riveted 3/4" PVC rings to these hinges to make finger holes. I ended up replacing all of these with 1" pipe rings. The 3/4" was too narrow with the rivet poking inside.
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I keep my first knuckle just before the hinges.
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Starting to come together. I finished adding the 1" pipe to the finger tips. Added screw eyes to guide the tendon pipes. Also added some 1" elastic looped around the plate to hold my hand down. And some 2mm foam to protect my knuckles from the hinges.
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The elastic is tight but needs to be in order to have the plate move.
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Each line was far longer than I would need. Always over do it on home runs.
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I started to add the tendon pipes. This worked out great with the screw eyes and cable tacks.
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I love the detail on this picture. This is where months of planning and design work pay off.
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The gap will have the small turnbuckles to add tension between the finger ring run and the K2 hand run lines.
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I need to keep both arms on at the same time. It's a both or nothing situation now as one arm is too heavy to stay on by itself without balance.
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Added the clear tubing on the bottom of the digits for the tendon line. Elastic is attached along the top. Lots of tape but it will be covered in 2mm foam.
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This has the left pointer finger completely wired up.
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To quote "The Princess Bride"
You just wiggled your finger, thats wonderful!

I need to move back the screwed down cable covers a little to allow the turnbuckle to slide back another inch. This will let the finger curl completely. But the concept has paid off. It's been a long few days but immense progress has been made.

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I called it early tonight to catch up on my sleep.
Tomorrow I plan to wire up the right hand and make all of the connections for both arms. Then I can begin encasing all of the mechanisms in foam.

I'll still need to use all of my free time for completing this project, but I have a plan and i'm sticking too it. I also practiced moving the puppet arms around while harnessed in and the range of motion is great. I'll still need to practice but it's working just as I had intended it.

6 days left Here comes Saturday!

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Today was a day of progress and setbacks. I have a ton of pictures to upload but won't be able to post them until tomorrow.

I glued together the 3D printed head and mounted the camera. But I put way too much bondo putty on the head so I need to sand most of it off.

I found the perfect hardware for the eyes and wired those up.

I finished the thumbs and began encasing the arms in foam. I've cut out the hand pieces and am ready to glue.
Unfortunately the power switch on my belt sander has blown out. So that took us down. Fortunately I don't think I'm cutting through anything thicker than 1 sheet. It will just be a little slower.

Head - 50%
Torso - 10%
Arms - 75%
Legs - 40%
Harness - 60%

3 more days, can he do it!
 
Are you going out of town the next couple of weeks? Celebration is 13-16th and I thought that was your goal.
 
Great job on the hand mechanisms. Very clever and effective. Can you get enough cable pull with your finger to close up K2's finger all the way?
 
Great job on the hand mechanisms. Very clever and effective. Can you get enough cable pull with your finger to close up K2's finger all the way?

They close about 70%-80%
I'll later change his hands to be cables linked to a linkage driven mechanism. So a very small motion on the cable will close his whole hand. That's K-2.0
 
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.
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Time for some primer filler on the 3d printed pieces.
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Everything got a coat or two. It really helped smooth things out.
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But i'll still need some bondo putty.... we'll get to that later :/
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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!
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Watching some twitch while I work. I've streamed some but no one seems to be watching while the world is asleep.
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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.
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Got pretty good with the bandsaw.
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Storage, not drying.
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Next piece to fabricate was the arm edges that touch the joints.
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This is the elbow. Again the bandsaw makes quick work of the foam.
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Test fit.
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Glued in the two end shapes.
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Cut some curved foam to add more glueable surface area.
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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.
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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.
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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.
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IMB_uDHjmL by drscifi, on Flickr

Counter sunk the mirrors in the ankle and wrist pucks.
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The ankle pucks.
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All joint pucks are done.
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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.
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While wandering around Home Depot, as I tend to do. I came upon these nylon hose elbows.
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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.
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The whole thing illuminates and disperses the light evenly.
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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.
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With the right angle they sit flush on the support shelf inside the head.
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And look AMAZING! Just what I wanted. K-2SO doesn't have Iron Giant glow eyes, he has irisis and pupils.
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His eyes are more like rings, and actually shift as he looks around.
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Wonderful.
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In gif form.
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I drilled out the holes on this little side chip.
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It will let some of those extra eye LED's through.
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Time for super glue.
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Did some streaming.
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It was so fun to put this puzzle together.
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Everything fits. Trying out a place for the spy camera.
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I'm going to moun the spy camera circuit board here so the power/status LED can be seen.
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Might use this LED or might use the eye white ones. Which will probably wash this one out.
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Temp holding the spy camera in place. Again, when the head is black you won't see the ribon at all.
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Marking out a cut out to hold the ribbon when the two pieces are joined.
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Trimming 3d Prints is interesting, you never know whats beneith the surface.
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Perfect.
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It sits flush.
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Time for super glue.
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The lip shelf was a great clamp spot while the glue set.
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Two tusks
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You can see how the filler primer really helps reduce or even eliminate the 3d print striations.
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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.
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Looking good.
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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.

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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.
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Ugh, added some more filler primer to try to cover up the clay. Welcome to stone golumn K2.
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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.
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The components of the inner mount. It straddles the "V" groove inside the top of the head.
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REM magnets will go on this plate, though I need to lower it some.
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Thumbs! Time to finally get the inside of the hands complete so I can skin the arms in foam.
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Working out the angle and placment of the thumb was tricky. Then mirroring it on the other side was even trickier.
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It wiggles a little, but you gotta have thumbs.
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The wired up hand.
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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.
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Yep, I'm Tony Stark.
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Same work bench. Time to start skinning.
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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.
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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.
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Scoring the top and bottom of the hands. Once I heat seal these they will open up some and look awesome!
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Ready to glue, but it's 5am so time for sleep.
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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.

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FOAM! Let's cut it up.

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Starting on a small piece. The back Cog and Bars port with antenna. Already blue printed this out. It's a little rough doing curves without the bandsaw but I manage.
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Drawing in the locations of the lights.
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Used some old wi-fi router antennas. I'll keep these unpainted to have a different texture.
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Need to make my lights red, tried making a gel with marker.
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Then found some craft beads.
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Taped the beads over the lights.
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Taped them down over the holes in the back.
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Instant red lights.
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Prepped for paint.
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Painted piece. Just need to add the pin-striping and glue in the antenna.
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Added in the side pieces of the hand plates.
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More plates.
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Plasti-dipped the bottom of the feet for extra resilience.
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I might add another coat later but the first coat is nice and thick.
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Finishing the forearms tonight. Used my cone maker program to get the angles right. 3" at the wrist, 4" at the elbow and 15" long.
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Using the 31" big fig and the 6" black series I pulled the detail lines from the forearms.
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The upper forearm will be an added piece of 2mm foam to add the stair step effect.
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Heat sealing the foam, also makes it pliable for bending.
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Scored the boxes which will open up with heat.
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Prepping a slot for the control linkages.
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Added a 4" support ring to the end.
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Trimming the opening a little earlier.
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Adde some support spacers mid way on the arm to keep it from being crushed with outside pressure.
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This feels like anatomy class. The arm is glued at the top. It was tricky to work out the sequence of glueing the seams. Started with adding the 4" at the elbow, then glued the arm to the wrist disc. Then closed up the under seam.
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Now it's already looking like an arm.
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Hung the arm on the skeleton.
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Closing up the second one, forgot to do the 4" first, so that was trickier.
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Two forearms done. You can see the 2mm added pieces to the top half. Also I heat sealed the first arm all at once which taught me, DON'T put a heat gun on an arm that is made of PVC! My pvc coupler started to melt. Fortunately I caught it before damaging the joint.
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Added stops to the knee joints. No chicken legs for K-2SO.
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Feet are done.
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Starting to work on the finger covers.
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Got some 123 Blocks after watching chinbeard talk about them on youtube. Have used them a ton. Here I'm holding down pieces of 2mm foam so I can add score marks. Each finger will be wrapped around with the foam in this superman shield shape. I can trim it down to each knuckles length.
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Speaking of chinbeard I got to catch his Q/A stream on Thursday (3/30) Asked him a question about budgeting time on foam projects, and was able to share this build blog. I hope he later had a chance to read through it. I've been watching a lot of twitch while working on K2 and am even prepping for some more over the next two weeks.
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Yes you heard right. K-2SO is not done. I came up a little short for my 4/1 deadline. I was disappointed I couldn't bring him to Wondercon this year, but he will make it for sure in 2018. But I'm still pushing through for my second deadline of 4/15. The So Cal RPF meetup! K-2SO and I will be there!
I've entered all of my remaining components into a master list in todoist. Only 67 left!

15 days until the RPF meeup

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Last two nights have been working on the finger covers. I've found a nice schedule for my evenings after work, time with family, dinner and some youtube. Followed by working on K2 between 9-12.

I took the scored sheets and cut them to length for each finger.
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Using my 123 blocks to support the arm. I discovered I need to be careful where I put pressure on the foam as it can still bend or dent. I'll need to work out some sort of jig or rig I can transport the pieces in. Also for storage so it's not damaged over long periods of time.
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Skinned the thumb and pointer finger.
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After the thumb is done I closed up the inside edge.
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Right hand all skinned except for the finger tips.
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Th palm of the right hand. I'll spray paint black the spaces between the covers at the joints.
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The next night I started on the left hand. Cut out all 15 pieces at once then stuck it all together.
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Most of the steps of this build are building one side, which takes a while to figure out. Then mirroring it on the other side, which goes much faster.
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I traced an extra cover strip that was glued in the shape of the finger covers. It had this guitar pick look. I trimmed out 11 or so pieces for gluing over the fingertips.
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Lots of glue to the fingertips and the fingertip covers.
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The fingertips are holding on nicely. When they are dry I'll trim off any excess around the edges with my sheers.
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Working 2-3 hours every night is giving me good progress but not killing me like my 9p-3a building marathons were. With the hands done I'll start work on the biceps and the shoulder bells tomorrow. I need to get cracking on the legs by Thursday. It's crazy how I felt I could finish all of this last week. Working steadily every night shows me how much work there is to do. 66 items on my todo list with 12 days left.

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I didn't get any more work done on K2 tonight but I did find 3 other cosplayers building K-2SO puppets and suits on Instagram! That seriously made my day.

@harteattackcosplay is building his for C2E2 in only a few weeks. I know how that feels.
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@the_cosplay_guys have a 3D printed head like mine and are going for a suit type approach.
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@imperial_rook has their K2 already walking! I can't tell if they are shorter or if their K2 is just very very tall.
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I love how we all have approached this project differently. How awesome would it be to all meet up once our droids are complete! Keep on building my new K2 friends.

66 items on my todo list with 11 days left.

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Evenings have been booked the last few nights so I was finally able to make more progress this weekend.
Friday I started on a side project of sorts. A Death Star Plans Cassette prop for K2 to hold. I didn't need anything 100% accurate and there are much nicer models you can get on the RPF site. But I wanted one that was made of foam and light enough for my droid to hold.

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Worked out the rough dimensions.
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I'll use some leftover PVC pieces for the static sinks on the side.
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Trimmed out the front discs.
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I'm going to make two copies so I doubled everything. Why make one when you can make two.
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All of the front and back discs cut and ready.
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Template for the two sides.
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Getting position dialed in.
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I cut the pvc in half for the side sinks.
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Trimmed a lot of 5/8" strips for the side pieces and inner support.
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Unglued placement of the side walls.
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With the top cover and with the top cover removed.
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I'll also add the pipes in the handle and glue some old ram to the bottom.
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A discarded lid served as the plastic pieces.
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Glued down the outer wall first.
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Only glue on the bottom and inner faces of the outer wall.
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Painted all the discs with my primer gray. Did detail work on the front pieces.
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Tried to only apply glue where needed on the back.
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Back discs in place.
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Super glued down the plastic to be sandwiched below the top piece.
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Finished front.
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Finished back.
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I also picked up a little more PVC to make my head stand. This would also help with assembling the pieces. When K2 is in storage the head will stay inside with me on this stand. Made out of 1-1/4" pvc pieces.
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Primer coat.
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Same black as the rest of K2. Added some leftover bumpers that I tried to use as joint stops.
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With the neck piece in its socket.
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Today was all about the head. I sanded down the bondo to a smoother texture over the whole head.
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Added a new coat of primer. I wasn't 100% satisfied but happy enough to move forward.
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This is actually with the black paint but the color balance is all off. It looks blacker than this image appears.
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Started adding weathering details as I went with silver sharpies.
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Glue ready for the neck ring.
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While contact cement was becoming tacky I installed the eyes.
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Glued down a strip of foam to be the new neck ring.
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Prepping the camera for installation.
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POV camera glued with a small wedge behind it. If I need to I can remove that piece to look ahead more.
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Painted, weathered and glued together.
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My plan is to install a shelf inside the head with REM (Rare Earth Magnets) to connect to the tripod head. I need them strong enough to hold the head on but not too strong to rip the mount out. Keeping 2-3 layers of 8mm foam in between them gives the right pull force.
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Marking the polarity side. Glued foam around the edges.
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Layered with tape.
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Did a test of the neck detail with a little ring of foam. Will detail the whole neck stalk.
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Confirming REM polarity before installation.
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This part took a long time. I reshaped the shelf to be the hight I wanted it and reenforced it to hold the REM. It took a while to find the exact place to glue the shelf that put the pan/tilt head where I wanted it.
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Added some super glue an tape to permanently install the pan/tilt head to the neck stalk. This can be done as the neck can be supported by the stand.
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Attached the POV camera battery to the pan/tilt. This way it's weight won't be on the tilt head.
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Glued in.
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End of a great day. Letting all of the contact cement cure before attempting to join the REM. Might need to fine tune the placement of the magnets etc. Hope to still be able to pan as well as tilt the head. Not a lot of clearance.
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Nocked off almost all of the head category tasks today. Also finished the DS plans cassette. Tomorrow night i'll start fabing the legs and try to knock those out.

Also know that I'll be brining K-2SO to the SoCal RPF party next Saturday 4/15. I hope to have him finished by then, but he'll be there in whatever state he is in.


58 items on my todo list with 6 days left.

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