Category Archives: Skins

R2 Updates

I’ve noticed that I haven’t been posting the updates to R2 on here for a while.

Well I got the foot drives done. They’re absolutely gorgeous.


Foot Drive


Foot Drive

I also got both legs completed, and got the shoulders attached. I then went on to glaze the seems. Still need to paint them.





I finished painting the skins and all the blue parts. Rob then came over and we attached them. At this point, it really started looking like R2 🙂

Center Foot Skirting

Center Foot Skirting

Then this past weekend, I started assembling the skirting for the center foot. I should be able to attach them to the foot this week and then finish off the outer feet.
Hopefully I won’t forget to post more as I go 🙂

Baby Steps

Didn’t get as much done this weekend as I would of liked. But had a great weekend none the less. Ended up doing more planning for our Disney Star Wars Cruise in January. Participated in a Golf tournament and just had fun.

Any ways. I did get a few more parts in. The springs needed for the foot drives as well as the delrin rod for the foot drives as well.

Delrin Rod and Springs

Delrin Rod and Springs

I was having a hard time finding these exact parts as most of the sites that carried them only shipped to the US. And the thought of driving across the border to pick up a 4$ order… meh.

Finally found them from a Canadian site. Well funny thing is, the next day, I got an other package from the same company. This one contained 5 laparoscopic surgery tools!


With the bit of time I had to work on R2, I glued on the panels on the skin that are never actually going to open.

Glued Panels

Glued Panels

I also decided to tape some of the doors there as well as placed the coin slots, just to see how it would look. I also fixed a bit of the alignment issue… think I might still have a bit to do on that.

I noticed, that the slots for the utility arms are off… that or my arms are off. I’ll definitely need to look into that as I do plan on powering them. If you take a close look at the charging bay, I also added the LEDs and the board to it. If you’re REALLY nice, you might get a video tonight with the blinky blinky lights.

Big R2 Weekend, big post

So I got alot of time this weekend to work on R2.

Started off by getting some new parts in and picking up some new parts.

Friday I got home to my shiny new Sabertooth speed controller for R2’s feet. I then went out and picked up some steal rods to build the shafts for the feet with, I also picked up more bits here and there.


Miscellaneous parts


More chain and the clasps to attach them

Cutting steal with a dremmel… not so great. So I had to go back out and bought some jig blades for cutting steal. Remember kids… don’t touch steal you’ve been cutting with your bare hands… it’s hot!


Steal Rods cut to size


I then continued work on the skins. I glued the inner and outer skins for the front together using e6000 and many clamps. Before gluing though, I sanded the inner skin and made sure no burrs were left.


Front skins glued together


While this set, I went back out to the garage and sanded the new radar eye. Once nice and smooth (well as smooth as you can get a 3D printed part), I applied a thin coat of glazing putty. The thing with glazing putty is that you don’t want to apply it too thick. So I’d put a thin coat, smooth it out, let it dry, then sand it, then rinse wash and repeat.


Glazed and confused


Eventually I got to this. You can still see some of the lines from the printing, but that’s why I got myself some filler primer. Once we’re at the painting stage, I’ll prime it and this special primer will fill in the rest of the gaps. Then I get to sand it some more and continue the fun.


Glazed and Sanded


Next up! More skins… Now one of the parts I’ve been dreading since I got the skins (probably why they’ve been laying around the living room for a few years now) is cutting the back skins to make an access hatch. Some builders access the inside of their astromechs by just removing the dome. Mine has too much stuff inside it, so I need a removable panel in the back to get in there. Unfortunately, the skins I have don’t have this hatch laser cut. Well not the inside skin at least. I removed the outside one, then attached the inside and outside skins together using tape. Now that everything was at the right places, I placed the outside hatch and placed tape to show where it lined up.


Lining up the hatch


Now carefully using my Dremmel and a metal cutting wheel, I started to cut… Now, safety first, I had a respirator, in order now to breath in any little bits of metal and safety goggles… yet some metal still ended up go under the goggles.
While working on this, my neighbour came by to see what I was working on. He knows I work on Star Wars costuming as he’s come by during my armor building parties. But a fully functional, life size R2? His mind was blown.


Cut Hatch


After several cutting wheels, I got the hatch out. Sanded it to remove the burrs and any sharp edges. Now I need to take all the panels out.


Assembling panels.


Now I started gluing the insides and outsides of the panels. More e6000 and more clamps. These will need to be glued onto the hatch as they won’t be opening up.


Completed hatch panel doors


Now the inside and outside parts of the hatch are being glued.


Gluing the hatch

At this point it was getting late on the last day of my r2 building long weekend. I decided to place the front skins on just to see how it fit. I haven’t attached them yet, as I need to make a trip to Ottawa Fastners to get some screws to attach the mounting blocks and some Set Screws to tap where I’ll need to drill.


Dry fit of the skins


Close up



Skinning R2

The legs, skirt, foot shells, foot drives and battery boxes are ready and about to be shipped!

So I got working on the skins.

At lunch today, I started cutting out some of the skin panels and getting rid of the burrs using a chisel. You basically just rub the flat side of the chisel on the edge and it smooths it out. (will be showing this in the next vlog entry)


Skins with panels removed

Skins 2

Panels being sorted out

Skins 3

Dry fit of the utility arms skin panel

Screw you R2 :)

Went to Ottawa Fasteners  this weekend to pick up some screws for R2 and some nuts.

The screws I got are for attaching the center Ankle to the frame’s ankle plate and for attaching the skin blocks to the frame.

The skin blocks are little pieces of machined metal that screw into the frame using 10-24 screws and then there’s tiny little screws in them that the skins attach to.

Coin Slot work



Well with the skins here, I’m kinda looking forward to working on them so I decided to start work on the coin slots. Since I seem to always miss the aluminum run of these, I had bought the resin one a while back. It’s not great but it’ll do for now. My main problem with it, was that the slots for solid. Completely full… So I took the drill to it and started making some holes in them in order to dremmel them clean.





Oh boy! If you’ve ever worked with resin pieces before… you know the mess it can make.

When I worked on the radar eye, I was smart enough to have the vacuum next to me as I worked so that it would suck up the dust as I went. This time… Ange had the vacuum downstairs as she was gearing up for her Girls’ Night… Need to clean this up when I get a chance. I also need to finish what I started here… the drill ran out of juice, so I’m charging it right now. I’ll post more pics to this post when done.

Skin Update


And I have no time to admire them, thanks to the *$^#($ deck.

Anyway. I picked them up at the postoffice after work. They’re way lighter than I imagined. But SOOO nice.











I am worried about starting anything but the panels on them till I get the missing parts for it like the Ports, Power Couplers and various vents. I’ll probably order the resin versions for now.

Also, mental note (guess not so mental if I write it down). Go to Ottawa Fasteners and get the hinges needed for the panels.


This is what the skins look like when you get them… there’s 2 layers for the front and 2 for the back… all laser cut, so there’s quite a bit of JB Welding to do and adding servos and hinges for the doors.
(These are not MY skins, just an example)

But!!! Mine are ordered!!! Never thought the day would come. Mainly cause I was terrified of ordering. Basically how runs work usually is.
  • Guy makes part.
  • Guy makes sure part fits with club specs
  • Guy shows part to council
  • Council approves run
  • Guy posts run
  • Guy takes payments
  • Guy tells buyer part is shipped
  • Buyer gets part
 Well this guy started making the skins before the forums existed. So he only ran off the yahoo group. You’d blindly send him money and at SOME point, skins arrived on your doorstep. No communications at all.
Well someone found him and called him and found out that not only is he doing an other run, but he has 50 waiting for a good home. So I jumped in. No comm… but I’m hopeful they show up soon.