Southern R2 Builders Group Forum Index Southern R2 Builders Group
A Place for Star Wars Fans
 
 FAQFAQ   SearchSearch   MemberlistMemberlist   UsergroupsUsergroups   Join! (free) Join! (free)  
 ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in 

Styrene Droid Frame Tutorial
Page 1, 2, 3, 4  Next
 
Post new topic   Reply to topic    Southern R2 Builders Group Forum Index -> Styrene Droid Tutorials
View previous topic :: View next topic  
Author Message
Please Register and Login to this forum to stop seeing this advertising.






Posted:     Post subject:

Back to top
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Wed Sep 08, 2010 11:44 pm    Post subject: Styrene Droid Frame Tutorial  Reply with quote

This tutorial is to supplement what Dave already has in his tutorial sheets.
Make sure you use Dave's sheets to help guide you through the build.
For me, It's sometimes easier to have a actual picture.

I hope this helps and there will be more tutorials coming soon.
Brenda has a tutorial on the Skirt and the Outer Ankle she will post soon.
As we build each part we will add more.

If there are any questions or something not written clearly, Please let us know.

HAPPY DROID BUILDING TO ALL AND TO ALL GOOD NIGHT    Laughing
Calvin


Last edited by admin on Sun Oct 03, 2010 12:22 am; edited 1 time in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 12, 2010 8:02 pm    Post subject: Reply with quote

In this tutorial, I will do my best to walk you through the steps to get your frame ready for skins. You will need to join and download the blueprints from www.astromech.com.

Once you have the plans, Call around to some of your local print shops for the best price and have the prints printed full size 100%.
You will also need some Tac Spray. You can get this at your local decorations shop.

As I go through this tutorial there will be additional tools you will need to buy and a few Jigs to make circles.
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 12, 2010 8:36 pm    Post subject: Reply with quote

The 1st and hardest thing to make is the rings for the frame.
You will need to buy a Router. I found this router at Home Depot and the price was under $100.00. This will be the most expensive tool you will have to buy during the build. Here's a picture of the one I purchased and it's light weight and easy to use.



The router comes with a separate base and you will need to attach it to the router. This gives you a larger cutting base and is much easier to keep the router flat as your cutting your styrene.



The cutting bit you will need is a 1/4 inch straight cut. You can also get this at Home Depot.

You will need a 24 x 24 inch piece of Plywood as a cutting base.
In the dead center of the Plywood drill a small hole to insert a screw from the backside of the plywood. This will be the center post to go through the styrene and it also is the pivot point for the router circle jig.

A circle jig for your router can either be purchased or you can make your own jig from 1/4 inch plywood or 1/4 inch plastic.
I made my own jig from plastic using a Jigsaw (Sabersaw).
After you cut the jig in a similar shape as you see in this picture, You will need to cut a 1/4 inch hole through the jig for the router bit to fit through.
Attach the router to the jig using some small screws.
With the router attached and the straight bit installed in the router you will have to make some measurements from the router bit.
The measurement you will need to drill the pilot hole in the jig is 9- 1/8 inch and another hole at 9 inch. Make sure the measurements are as accurate as you can get them.





I know this seems like allot to do just to make the frame circles,
But don't let this stop you from building a droid. If you have a friend that already has a router then it may be easier to let them cut your circles.
As far as expense in buying the tools, Believe me the styrene build will save you so much money in the long run the start up tool expense will be nothing in the end.
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 12, 2010 9:18 pm    Post subject: Reply with quote

First I want to say I'm sorry if I don't have a picture of everything for the tutorial, But I will explain everything that you will need to do.

Start with the bottom rings for your frame.
On your sheet of styrene measure a 20 x 20 inch square, Then from corner to the diagonal corner with a straight edge mark a line.
Then do the other 2 corners the same. What your doing is marking a cross hair or X across the styrene. Then cut out the 20 x 20 square. Where the X cross this will be the center of your 20 x 20 inch styrene. Drill a hole at this point the same size as the hole drilled through the Plywood and through the router jig.
Place the styrene down onto the Plywood making sure the screw through the plywood is sticking through the hole in the center of the styrene.

On blueprint marked Body Frame 1, Cut between the circle and the other frame parts. Right now all you need is the circle print.

Tack spray the back of Base Plate 1 print and attach it to the 20 x 20 inch square styrene. Be sure to get the center mark on the blueprint on the screw sticking through the styrene and flatten the print out smooth.
Take care in these steps as they are very important.

Using a metal ruler, Scratch any lines you see on the blueprint.
These are the marks for the upright frame parts  to be glued later.
All of these marks are important and don't scratch them to deep, But deep enough you can see them once the blueprint is removed.
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 12, 2010 9:27 pm    Post subject: Reply with quote

Ok, Your ready to route your Base Plate 1.
Place the router with the attached Jig on top of the blueprint.
Use the 9- 1/8 inch hole in the jig, This will give you a rough cut.
Put a nut onto the screw you have through the entire setup.
Hand tighten the nut.
Run the router around the circle 2 times, Then reverse the direction
1 time.
Remove the router and clean the top of the styrene getting all the shavings off. Replace the router using the 9 inch setting.
Run the router around 2 times and you will have a clean edge on the
styrene.
Here's a picture of how it looks after it's routed.



You can see all the lines are scratched, The center hole and there's 2 mounting holes you need to drill the same size as the center pilot holes.
Those 2 solid lines on each side of the plate need to be cut off.
After you cut them off and remove the blueprint the Base Plate 1 will look like this picture.



Mark this plate as Base Plate 1 and put it aside for now.
You've just cut a main part of your frame!!!!!
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 26, 2010 12:28 am    Post subject: Reply with quote

In the plans cut another 18 inch circle the same way as you did in the previous post. Dave E. bonds these 2 plates together and this makes the inner frame 1/4 inch thick and adds allot of strength to the bottom of the frame.
When you bond the 2 plates together 1 plate will have small etched marks near the edge and 2 long etched marks.
These marks need to be seen from the bottom of the frame.
The other plate has etched marks along the 2 round sides.
These are the frame vertical marks. So make sure you can see all these etches when you bond the 2 plates together.

Spread Weldon 3 all over the plate ( You will need help and work fast).
Use some small screws in the center holes as guides.
Press the 2 plates together, Just be accurate because once these plates touch they don't want to come apart.
Let them dry overnight .
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sun Sep 26, 2010 1:01 am    Post subject: Reply with quote

Using the plans to cut the vertical plates are next.
These are cut using the OLFA knife.
Cut the styrene several times until you think your about halfway through the styrene. It should snap apart fairly easy, If you have cut deep enough.
Remember, It's not how hard you push down to cut the styrene, It's the amount of cuts you made which is the magic to cutting styrene.
After you have a cut part, Use a Mouse Sander and just LIGHLY clean up the sides where you have cut. This will give you a much better joint.

In these pictures you can see how the 1st layer of verticals come together.
Make sure you use a small square and some steel corner brackets (available at Home Depot) to set each vertical. Don't rush this part.
Use Weldon 3 and a applicator bottle, Wet the bottom plate where the vertical will be placed. Place the vertical in place and square.
The Weldon will tack in a few seconds then put the brackets up to the vertical for about 5 minutes. Make sure to keep everything square or you will hate it later.




Once you have these 4 verticals, Start on the other end.



There are 2 larger verticals that go on each side where the flat area is located. Once your frame looks like this picture, Stop.
Allow the frame to dry overnight.
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Mon Sep 27, 2010 12:22 am    Post subject: Reply with quote

Now that the lowest verticals have been glued and dried, It's time to put the 1st frame ring in place.
Place the 1st frame ring on top of the verticals, Place the ring so the etched marks are facing up so you can see them. Check around the ring and check the verticals are lining up with the etches.
Use Weldon 3 and start at the front of the frame. Lift the ring just enough to wet the top of the vertical. Set this vertical and check the alignment of the other verticals, If all looks good let it dry 5 minutes.
Across from the vertical that is bonded, Glue another vertical.
Keep doing the crisscross pattern until all verticals are bonded.
If some of the verticals do not line up perfect, Try to adjust them.
I placed the Weldon can on top of the vertical I was gluing to help hold the position.
This is what you should have now.

Back to top
View user's profile Send private message Send e-mail Visit poster's website
Blsith



Joined: 24 Aug 2010
Posts: 191

PostPosted: Mon Sep 27, 2010 5:34 pm    Post subject: Reply with quote

admin wrote:

In these pictures you can see how the 1st layer of verticals come together.
Make sure you use a small square and some steel corner brackets (available at Home Depot) to set each vertical. Don't rush this part.


Just as some feedback - thanks for this.  I never thought about some corner brackets like this, as Dave's plans just call for set squares.  This is an awesome way to get this done easily, though.  

The pictures you have help out a lot, too.  Keep up the great work!  You are definitely making me anticipate my styrene order coming in at this point!
Back to top
View user's profile Send private message AIM Address
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Mon Sep 27, 2010 9:06 pm    Post subject: Reply with quote

Thanks for the comment  Very Happy
I hope this tutorial takes some of the questions out of building a styrene droid.
It's really easy to build.
Calvin

Back to top
View user's profile Send private message Send e-mail Visit poster's website
Display posts from previous:   
Post new topic   Reply to topic    Southern R2 Builders Group Forum Index -> Styrene Droid Tutorials All times are GMT
Page 1, 2, 3, 4  Next
Page 1 of 4

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

Card File  Gallery  Forum Archive
Powered by phpBB © 2001, 2002 phpBB Group
BlackAndWhite style created by feather inju
Create your own free forum | Buy a domain to use with your forum