Building 

R2D2


04/04/20 - 3 items have been updated:
- After 3 months of prototyping parts and revising the design,  I'm releasing the Outer Foot Drive & Shell design using .188 thick styrene. The basic design has not significantly changed. Tab and slot clearances have been adjusted to make the assembly easier and the parts assembly sequence has been adjusted to take those changes into account. I've left the original set of instructions up on the website and recommend that you review those instructions BEFORE you look at the new .188 version instructions. As always, if you have ANY questions at all please ASK! It's a lot easier to clear up confusion before you glue parts together than it is to try to pry those parts apart after you find out your guess was wrong.

- I've added some drawings to the Box Beam Legs Assembly instructions. My design for the legs was done when .250 styrene sheet was available. When it became unavailable, the design was converted to use 2 layers of .125 styrene, the drawings however were not updated. The new drawings are designed to clarify what thickness, and how many pieces, are being used during the assembly.

- Order list has been updated.

11/17/19 - I have converted the NextGen Frame over to using what I'm calling a Tab Core. No PVC pipe, No Sliders. Makes it easier to manufacture and assemble. Description here. Since I'm making changes I'm going to solicit suggestions for other changes to the NextGen Frame. One suggestion, made a while ago, is to provide 2 of the dome drive spur gear. Doubling up it's thickness makes aligning the drive gear with the mating ring gear easier. Have a suggestion of your own? Send me email: fpirz (at) media (dash) conversions (dot) net.

10/06/19 - My CNC shop has advised me that they can no longer get sheets of .220 Styrene. The industry has changed, yet again. Several years ago I had to change from .250 to .220. Now the change will be from .220 to .1875 (3/16 - also called .188). I've been using .188 for a few years now in new projects where rigidity is required. This change causes problems for four R2 parts packages: CS:L Eggcrate Frame, The Eggcrate Center Ankle, The Legacy Center Foot and the Outer Foot Drive & Shell. Fortunately I've already been developing alternate designs. The Hex Center ankle replaces The Eggcrate Center Ankle. The SAK Center Foot replaces the Legacy Center Foot. I have re-designed the Outer Foot to use .188 instead of .220. I'm working on the CS:L Frame design.

09/14/19 -
With more than a little reluctance I'm announcing a price increase for 3 of my parts packages: Battery Boxes, Outer Foot & Center Foot. More info is on the R2D2-CNC pages. Other Developments -  Shoulder Horseshoes are out of prototype and available with complete assembly instructions. Chopper's Legs are in version 1 of prototype - assembly is going slowly.

Current Shop Status 01/04/19: The Shop has re-opened.
For Order Status see the  2020 Orders List.


For the packaging and pricing for CNC cut parts packages see my web page at: www.r2d2-cnc.media-conversions
For the pricing for 3D printed parts see my web page at: www.r2-3d.media-conversions.net

Frank Pirz
Media Conversions LLC

Welcome to the Media Conversions  R2D2 Construction web pages.

Background - A little bit about me and why I want to build a full sized replica of R2D2.

R2D2 Construction
There's lots more to building a Droid than meets the eye. Particularly if its going to be mobile.

CS:R ANH NextGen Frame
assembly instructions
CS:R NextGen Frame - Conversion to Tab Core
CS:R Utility Arm Box
Dome Motivator

Engraved Skins -
CS:R ANH and CS:L ANH versions both available
2 Layer Skins
Engraved Skins
Mounting Engraved Skins

The CS:L Eggcrate Frame (Will have to be updated to .188)
assembly instructions
The Skirt
assembly instructions
The Fixed Shoulders - a design error with the Box Beam Legs has a minor impact on the Fixed Shoulders (see note)
3-leg Shoulders
assembly instructions
2-leg Shoulders
assembly instructions
Dome Motivator for Legacy Styrene Droids

The Box Beam Legs 
assembly instructions
Shoulder Horseshoes
assembly instructions
The Hex Center Ankle
assembly instructions
The Eggcrate Center Ankle (replaced by the Hex Center Ankle)
assembly instructions
The SAK (Swiss Army Knife) CS:R Center Foot
assembly instructions
The Legacy Center Foot (replaced by the SAK Center Foot)
assembly instructions
The Outer Foot - showing integrated assembly of:
The Outer Foot Drive
assembly instructions (Previous Version)
assembly instructions (New .188 Version)
The Outer Foot Shell
assembly instructions (Previous Version)
assembly instructions (New .188 Version)
The 3D Printed Battery Box
assembly instructions

Body Parts

Utility Arm
Utility Arm Box

Document Packages
For the longest time I've been embedding my Document Packages (.zip files containing drawings in both .pdf and (autocad) .dwg format) in with the web pages that describe the parts. Unfortunately I have not been completely consistent in the way I formatted the links to those packages. To fix that problem I've brought all of the packages, and their links, together here.

Parts Packages
I have been approved by the R2BC Builder's Council to offer CNC cut parts packages based on the designs I have posted here.
Additional information on the parts packages is on a separate set of web pages. See:  r2d2-cnc.media-conversions

DroidCon II
Media Conversions attended DroidConII and Presented two talks. See all of the DroidConII material here.

3D Models
As part of the design process I create 3D models of the R2 parts that I'm building.
I'm using Alibre Designs 3D design package and I'm publishing the models in STEP AP203 (.stp) format in English (inch) units.
The Models have been given a separate set of web pages.   The 3D models page is here.

Robot Library
Useful reference items


Information Sources - The R2 Builder's Club and Astromech.net lead the list!
Health Hazards of the various solvent glues typically used in building R2.
Plastics Suppliers and Styrene Prices
Design Choices: Styrene or PVC, Which Glue & Plastic Thickness
Supplier Links

Contact Information
Contact me using: fpirz (at) media (dash) conversions (dot) net

Legal Notices
R2D2 is copyright by LucasFilms Ltd. All other material on these pages is copyright Media-Conversions LLC.

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