tag:blogger.com,1999:blog-68451035140937508672024-02-21T23:12:41.814-08:00Droid CentralKevin Zirkelbach's styrene droid building progress.Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.comBlogger80125tag:blogger.com,1999:blog-6845103514093750867.post-62644708580437651782019-10-01T15:18:00.000-07:002020-07-30T15:19:08.899-07:00Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-42454330110928005202017-09-25T14:07:00.001-07:002017-09-25T14:07:20.679-07:00Milwaukee MakerFaire 2017This year's MakerFaire had the largest group of builders in the booth yet! We had six builders with a wide variety of R2 builds as well as some additional non-R2 droids and props.<br />
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The Milwaukee Dalek Asylum was hosting a Dalek costume contest in conjunction with an attempt to break the Guinness Book of World Records achievement of 95 Daleks.<br />
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My R2 Dalek costume was a hit, and elicited a wide range of reactions from makers and attendees. While I did not win anything in the costume contest, I was part of the world record. We had a total of 107 Daleks/Dalek costumes to set the new record!<br />
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Speaking of awards, it turns out the head of the Dalek builders nominated us for and award, which we won! We were awarded a Blue Ribbon as the "Maker of Merit"! What a nice surprise to cap off a great weekend!<br />
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But overall, as always the reaction from the kids really made the event worthwhile and I hope that we inspired some new droid builders!<br />
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<tr><td class="tr-caption" style="text-align: center;">R2-DLK</td></tr>
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<tr><td class="tr-caption" style="text-align: center;">An interactive C-3PO head that I 3D printed</td></tr>
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<tr><td class="tr-caption" style="text-align: center;">Steve Radtke's adorable mini GONK droid</td></tr>
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<tr><td class="tr-caption" style="text-align: center;">The surprise Blue Ribbon our group earned as "Maker of Merit"!</td></tr>
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-10318835813936070172016-11-05T10:27:00.001-07:002016-11-05T10:27:06.416-07:00Discovery World Sci-Fi DayWell I completely flaked out and forgot to post about the Sci-Fi Day at the Milwaukee Discovery World Museum! While there were not as many costumed characters as last year, because politics, but there were still a great number of people in attendance and a nice showing of R2 Builders. Thanks everyone for all of your hard work!<div>
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It was especially fun to see the kid's reactions and to see some really excellent costumes!<br /><div>
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-79769232375828828312016-09-26T18:57:00.001-07:002016-09-26T19:19:14.361-07:00Milwaukee MakerFaire<br />
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It was time again for the Milwaukee MakerFaire and the R2 Builder's Club was out in full force! Besides myself, we had Craig with his awesome menagerie of droids and creatures, Steve with his beautiful wood and aluminum work-in-progress R2, and the other Steve (there's two of them!), the Usian Bolt of droid builders who has his beautiful R2 there which he completed in 8 months!<br />
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I was able to put the new dome and the scooter motorist the test. I took R2 for several trips around the MakerFaire, meeting fans and making new friends. It was great to see excited the kids got, and R2 was feeling the love!<br />
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-74739546716037512242016-09-21T19:07:00.000-07:002016-09-21T19:07:37.032-07:00Radar Eye RedoAt long last I 3D-printed a new radar eye. The first I printed had a flat back on it and would not sit flush against the dome. Doh! This second one I reengineered to be hollow and I am keeping my fingers crossed that it will fit adequately. I will install it tomorrow in time to finish up the dome for the Milwaukee MakerFaire on Saturday.<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-62506490757991829422016-08-08T08:34:00.002-07:002016-08-08T08:35:52.123-07:00New Radar Eye LensI 3D-printed a new radar eye lens for the new dome. It turned out great, up until I left the primed lens out in the sun and the heat caused it to shrink and dimple.<br />
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Attempts to smooth out the lens with putty failed, so I printed a new one. I added a larger flange around the the base and it fit beautifully.<br />
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A little sanding, some priming and several light coats of gloss black and BOOM! Shiny new lens!</div>
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I love doing everything twice. Makes me feel like I am at work.</div>
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-18634190244293689972016-07-14T08:20:00.002-07:002016-07-14T08:20:39.545-07:00Blue Clear CoatI got some DupliColor Clear coat for the blue dome parts and I have to say that the results were very impressive. The clear coat evened out anything that looked a little mottled and did not diminish the color at all. It gave them the subtle, glossy finish that I was hoping for!<br />
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I plan on redoing the chrome on the dome with DupliColor Metallic Silver and then clear coating that, with the hopes of recruiting the same results that I had with the blue pieces.<br />
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Wish me luck!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-65063789576112628502016-06-18T09:10:00.002-07:002016-06-18T09:10:38.788-07:00Painting the Blue Dome PartsI started painting the blue dome parts using the Dupli-Color Sonic Blue Pearl paint that was recommended by the Builders Club. If the weather cooperates this weekend, I may be able to get all the blue parts painted, including repainting the booster covers so they match the dome.<div>
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I am very happy with the color. It is a nice purply blue, with subtle metallic highlights.</div>
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-11486004857975456942016-05-22T09:51:00.003-07:002016-05-22T09:51:24.857-07:00Chrome Dome PaintingAfter some filling and much sanding, I finally got the dome ready for chrome painting. I used Krylon Aluminum/Metallic Cover Maxx from Wal-Mart, which was recommended by the R2 Builder's group. My first coat turned out dull and splotchy, which I discovered was due to the fact that it was too cold outside when I painted it. Fortunately, the next weekend was warm and sunny, and I let the dome sit in the sun for a while before I started painting. That, along with shaking the crap out of the can of paint helped the next coats turn out quite well. I may do another coat to get a few spots that need a little touchup.<div>
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-221009930903700922016-05-01T15:26:00.002-07:002016-05-01T15:26:56.991-07:00Dome Prep and PrimeWell, it has been a busy month but I was able to glue the two parts of the new dome together and to fashion a dome ring from the floral MDF rings from Michaels.<br />
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I then cut out the holes for the holoprojectors, the psis and the front and rear logics.<br />
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I primed it today and later in the in the week I will do another pass of fine sanding and then a little more primer.<br />
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I have front and rear logics on order from Hyperdyne and am super excited!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-67499994383517336622016-03-22T19:25:00.001-07:002016-03-23T06:08:38.981-07:00Laser Cut Styrene DomeI was able to procure one of the fine laser-cut styrene dome from Astromech.net before Christmas. Even with the laser cutting, it required a fair amount of cleanup and sanding.<br />
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The dome has three parts. A whole inner dome, the laser-cut outer dome and the bottom dome ring. I used Brian Munger's excellent website that detailed his styrene dome build as a guide for assembling mine. You can check his build at <a href="http://www.bmunger.com/R2/gallery/dome-3/">http://www.bmunger.com/R2/gallery/dome-3/</a>.<br />
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After the initial trimming of pieces and sanding, I used Weld-On to glue the inner and outer dome together.<br />
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I bought some 18" MDF floral rings from Michaels to use as the inner support for the dome. I am going to attach that to the bottom dome ring with bolts and then glue the floral rings to the inside of the inner dome. I used 3M tape to put some temporary foam board blocks inside the dome to help me find the correct placement of the MDF ring.<br />
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I want to cut out the holes for the holoprojectors before I mount the dome to the floral ring so that I have more room to work. So far I am really happy with how everything has come together!</div>
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-68363674595838679592016-01-08T13:16:00.002-08:002016-01-08T13:16:57.352-08:003D Printed Radar Eye and Logic Display BezelsThere has been an increasing number of files available on Astromech.net for 3D printing R2 parts, and since I am building a new dome I decided to 3D print the radar eye and logic display bezels.<br />
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The 3D-printed pieces really turned out nicely the Dremel Ideabuilder printer. They were printed at highest quality, with 3 shells and a 35% infill. I started sanding the radar eye last night and the PLA sands beautifully. I am using a 120 grit sandpaper on my Dremel Multimax tool.<br />
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I plan on printing the holoprojectors as well since I found Vickers Viscount 3D print files that someone had posted online. Thank you inter webs!<br />
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com2tag:blogger.com,1999:blog-6845103514093750867.post-87652696481569459872015-11-15T19:04:00.005-08:002015-11-21T07:16:59.602-08:00Dome Drive GearI was unhappy with the performance of the BaneBots wheel that moved the lazy susan for my dome, so I designed and 3D-printed a dome gear for R2 on the Dremel IdeaBuilder printer at work.<br />
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I had some initial quality issues withe the 3D-printed pieces, but that was my fault due to the fact that I did not properly level the build plate. Doh!</div>
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The gear was made from one piece that I printed four times. The four pieces tabbed together to make the whole ring. I then sandwiched it between two rings of Sintra to make it more sturdy.</div>
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I 3D-printed a motor gear so that it would fit over the 1/2" Banebots shaft on my Jaycar YG2738 dome motor. </div>
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I have to say that I am very happy with the results, and the dome stops on a dime!</div>
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You can see a video of the dome drive in action also on YouTube:<br />
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com3tag:blogger.com,1999:blog-6845103514093750867.post-57381908252887075022015-11-09T06:07:00.001-08:002015-11-09T06:07:01.389-08:00Sci-fi Day Discovery WorldI has taken me a while to update the blog, but here are some pics from the great time I had at Sci-Fi-Day at Discovery World in Milwaukee.<br />
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The R2 Builders Group had a dedicated space and there was an amazing array of Droids and other robots, including Wall-E and a Dalek! The space was very nice as it had the droids roped off from the public, which cut down on selfie photo ops, but limited the amount of abuse the droids took at the hands of the curious and excited.<br />
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Also, it was my first time trooping as a Jedi with the Rebel Legion, and it was a blast! The kids were great, the other super fans were awesome and there were so many great cosplay costumes as well!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-59000456748750560152015-10-11T07:10:00.001-07:002015-10-11T17:32:18.619-07:00WeatheringWell, I have finally jumped in and started weathering R2 to give him some more authenticity. I am going for a patina of grime that is somewhere between grimy Tatooine R2 and throne room clean R2. I am using watercolor paint so it is easy to remove if I overdo it, and I plan on adding several coats to vary the color and detail.<br />
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After my first initial trepidation I am really start to enjoy it!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-58743733362424441702015-10-10T19:05:00.000-07:002015-10-10T19:15:49.486-07:00Milwaukee MakerFaireFinally getting around to updating the blog!<br />
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MakerFaire was two weeks ago and it was fun, frantic and just a wee bit frustrating. </div>
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The organizers combined my booth with my friend Bob Trocke's booth and that of another builder, Craig Smith. We three builders got a 20x20 corner booth and it was a great setup. Craig had a lot of cool droids he had built over the past 20 years or so - scratch built R2 (with awesome Weber grill dome), naked C-3PO from Episode I, the spider droid from Return of the Jedi - to name a few. He has some mad building skills and was an excellent booth mate!</div>
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Things got off to a rocky start. During setup on Friday, a freak accident short-circuited my Sabertooth 2x25 motor board in an impressive cloud of grey smoke. Fortunately, I had a spare at home that I swapped out that night and got him operational. Then unfortunately the next day I soon discovered that I was getting crazy amounts interference on my Vex 72Mhz controller. R2 had a tendency to dart off at full speed in random directions. Very scary. Could the interference be from, say, the robotics competition that was across the aisle from my booth? I wonder!</div>
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That was disappointing since I did not really get the chance to try out the new scooter motor drive at the show. I have since upgraded to a 2.4Ghz controller an hopefully this will avoid any future interference problems.</div>
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Regardless of R2's performance, the show was amazing! My brother, Pat came up for the day from Chicago to help out at the booth along with my son, Austin. I was glad they were there since there were over 30,000 visitors on Saturday and at times the crowd was 4 or 5 people deep around the booth. Despite the crowd, people had fun taking pictures with R2, and I enjoyed talking to people about the Builder's Group and showing them the Dremel 3D printer. It was especially nice to see friends and coworkers who came to the show.<br />
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Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-18188623886165224622015-08-21T17:40:00.000-07:002015-08-27T05:42:45.635-07:00Scooter Drives are GO!<div class="separator" style="clear: both; text-align: center;">
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The feet need some reinforcement so they don't snowplow when going in reverse, but I could not be more pleased with their performance! And this is at 12V of power - half the rated voltage for these motors!<br />
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A higher rez video can be found on YouTube: <a href="https://www.youtube.com/watch?v=IK6d5Pp4qlg" target="_blank">https://www.youtube.com/watch?v=IK6d5Pp4qlg</a>Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-34169868141823174462015-08-15T19:21:00.000-07:002015-08-15T19:21:02.528-07:00Scooter Motor Foot BuildI finally threw in the towel on my Jaycar motor foot drives. I just cannot make the drive hubs stay securely on the motor shafts. So, on to bigger and better feet!<div>
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After browsing the forums I came across the plans for the Razor scooter foot drive setup. I ordered the 130W 24V motors, the scooter wheels and belts from monsterscooterparts.com.</div>
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I cut out the plans from Sintra and tried to figure out its assembly. After some noodling around with the plans I decided to modify it to make the frame beefier, and to provide more support for the motor.<br />
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Three rounds of prototypes later, I have created a simplified scooter mount frame that I am making out of 1/2" plywood. The motor will be secured with the three bolts on the face, and I will eventually have extra support and brackets on the back end to keep the motor from torquing during operation.</div>
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I will use the adjustable threaded eyebolt assemblies that came with the scooter wheels to pull back on them to keep the belt taut. Tests with a 12V battery on the final prototype seemed very speedy and I am quite excited!</div>
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I am going to order some omnitrack casters for the rear of the feet, but until they come I will get some temporary ones from Home Depot.</div>
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I plan on building new foot shells that will drop over the frames and secure to the wood frame with screws that will be hidden behind the battery boxes.</div>
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Excitement levels are high I tell you! High!</div>
Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-14669388698296859362015-05-04T11:47:00.003-07:002015-05-19T06:55:50.861-07:00Kenosha Public Museum Maker FairI had a great time Saturday, May 2nd at the Maker Fair at the Kenosha Public Museum. There were about 8 or so other maker organizations there, including the Lance Middle School Robotics Club to the Milwaukee Makerspace group. About 350 to 400 showed up and everyone seemed glad to see R2!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-10572639516052388902014-10-16T07:20:00.001-07:002014-10-16T07:20:56.285-07:00Milwaukee MakerFaireI represented the R2 Builders Club at the Milwaukee MakerFaire on September 27 and 28 at the Wisconsin State Fairgrounds. It was a great time, showing off R2 and Austin's mouse droid and spreading the word of the builder's club. I also made some great contacts including Jesse Ransom from Sector67 in Madison (sector67.org) who are making some amazing projects!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-61840793057129442282014-07-27T14:27:00.001-07:002014-07-27T14:27:25.266-07:00Battery Box CablesI got the connectors of for the battery cables from my good friend Don Jarr on Ebay. He has a wide variety of high-quality resin R2 parts. I did not feel like scratch building these.<br />
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I got the "cables" from the miscellaneous bin of plumbing parts at our local Habitat Restore. A few cuts with the Dremel tool to remove the ends and few coats of paint and they are ready to go!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-75572762209596922032014-07-27T13:11:00.000-07:002014-07-27T13:11:02.404-07:002014 ProgressWell, needless to say it has been a busy year and my blog has languished. But, fear not! Some progress has been made no my droid since last winter.<br />
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Here are some new pics of the battery box build. I found some cool bolts that may bot be club spec, but I really wanted to use them since they belonged to my Father-in-law. If he was still around I am sure he would be helping out with this build!<br />
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<b>Battery Box Priming</b><br />
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<b style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;">Battery Box Bolts</b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh54z4UgaWZLaJHQpOIJrRhIcap2QRmRbEc24xfzt4Ok6K_WwhgmOFv7jrSssK5bLY3crDTi6kGqhdwmUdYx_GGsuO5dScAspMGSdtHBm-wKAUf_0mUsz0k6N-BQxBEZplWHbV_EiYpQCE/s1600/IMG_0603.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh54z4UgaWZLaJHQpOIJrRhIcap2QRmRbEc24xfzt4Ok6K_WwhgmOFv7jrSssK5bLY3crDTi6kGqhdwmUdYx_GGsuO5dScAspMGSdtHBm-wKAUf_0mUsz0k6N-BQxBEZplWHbV_EiYpQCE/s1600/IMG_0603.jpg" height="240" width="320" /></a></div>
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-48000894383075492682013-11-21T14:38:00.002-08:002013-11-23T11:26:22.385-08:00L.E.D Belt BuckleHere is a video of the lights and L.E.D. belt buckles going. I have to reprogram the front light characters, but you get the idea.<br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dyVYYjswdh3oEXzSwLKuylatm400GDPFT9mzWl9kYBvN6qRd-8u2ZizxXKQDMT5dqG-NuoMrz_kTdDTndyBlw' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-21010251740089030272013-11-03T18:01:00.002-08:002013-11-03T18:01:40.908-08:00Trick or Treating R2 and U.F.O.Well, it was a mad dash to get R2 reassembled and moving in time for Trick or Treating today! Once assembled I had to get all of the motor wiring attached, battery boxes mounted, dome lights installed and the front foot working.<br />
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The front foot was very problematic. I had finished the detailing on the sides and built out the skirt only to discover that the skirt was dragging in the back. So I used my Dremel MultiMax to trim some height off the foot skirt, but the caster was also being very flaky. I wound up buying a new rubbery caster at The Home Depot since the plastic one I had was not turning very well and was skittering around. I am still not happy with how the caster performs but it was OK for today's outing.<br />
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Kids and parents alike were very excited to see R2. Many wanted to take pictures and some were curious as to how he was built. Some people stopped their cars to get out and look! It was a lot of fun!<br />
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I helped my son build a "crashed U.F.O." as well with an extra clear dome like the one I used for R2. He illuminated it witjh lights and had his fog machine cranking out smoke. Good stuff!<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0tag:blogger.com,1999:blog-6845103514093750867.post-54668306241270122042013-09-02T18:26:00.002-07:002013-09-04T17:35:56.596-07:00Feet are complete!I finished the feet this weekend and took advantage of the extra day off for Labor Day to get them painted. I am very happy with how they turned out. When I started putting the side details on a realized that I could put an extra skin of 1mm styrene on the other sides. This corrected some construction defects and the edges where the sides meet the back and the front turned out especially well.<br />
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I simplified the half moon construction, since most people won't even notice the missing detail. I filled the small gap between them and the sides with a thin bead of latex caulk which all but disappeared after the final coat of white satin paint.<br />
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I started on completing the center foot which had been damaged when I knocked it off my workbench. Doh! I am doing the re-skin process on that one as well. Stay tuned.<br />
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<br />Kevin Zirkelbachhttp://www.blogger.com/profile/03517745129195969567noreply@blogger.com0