June 27 & 28 2009

Creating a mold for the skirt ribs. Here's wood the original.

6 individual copies were made for making a 6 pack multi-mold

Pounding out the bubbles

Moose getting ready to remove the plugs

The first pour

Here they are, the first set of copies!

WOW - they fit!

Getting the skirt ready for making a fiberglass mold

Giving it a foam backing for strength

Needs more sanding

We had such a busy weekend that Syrena finished the router work and test fitted the frame on her R5-A1

R5 must die for serving Lord Vader!

June 23 2009

The weather doesn't look too good

bring down the door it's storming outside!

that didn't last too long

finally some frames gettng ready for glue!

June 21st 2009

WOW - this must be close to a record for putting together 4 droid's frames!

Jason and I even got a little work on the Skirts done too!

June 20

A very busy and productive weekend!

we started building at Moose's

Continued at our house

R2 agreed to show his parts

Seth and KITT supervised

Look at all we got done!

Finally we finished in the pool at around 11:00 PM!

American Cancer Society Relay for Life

R2's brown legs have been bothering my for a while. They look great on Patches, but R2 wasn't happy. With only a couple of hours before the Relay for Life I decided on a quick and easy plastic skin job for the shoulder areas.


This will get sticky and messy, so R2 had cover up


I had some helpers too



Sorry - some progress pictures are missing, but here's the end result



It is always at the last minute that we are getting ready

With no photographers along we snapped these few pictures using my phone.
Moose, Jen, and Patches we missed having you there!

Thanks Dan for including us in this great event!
Thanks Jeremiah Skywalker for coming all the way from Central Iowa to troop with us!

Waaaa

I fried my think geek sound card! The 5V DC regulator fried sending 12 V DC through the sound card - the end.

June 9 2009 Skirts

I forgot my camera again so there's only these 2 pictures from my phone.


After much trial and error getting the angles correct we cut the side pieces of the skirt.

No R2 progress - I've spent the past three days on the exhaust project from HELL!

Almost finished with the last few welds when the wire feed motor on the welder died!

Getting wired for sound!

Wired and mounted 2 wireless receivers matching Andy's mapping on the 'main' R2 boards (white wire = 10)

I quickly put together a 5V DC regulated power supply eliminating the need for batteries in the T-Shirt sound box

Ready to install!