Category Archives: Drives

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 🙂

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



Ankle Away!

Yay the center ankle was just shipped! Next on the list? Foot drives with motors! R2 will be moving around by the end of September!

And I think I found some… that are affordable.

These units are custom built using heavy 12g steel welded at 12 points.

They’re low profile so it won’t look like R2 is floating.
Nice thick rubber wheel.
Motor mounts are 12″L x 3″W x 4 1/4″H Weight 8Lbs each. And motors come with it!


The last set I was looking at, cost more, and I had to get everything from the wheels, chain to the motors separately.

And here’s what they look like.