Made it to Emerald City Comicon (finally)

I'll try to post more later, but here's a tiny bit about the first day at ECCC.  Everyone loved the full size Lego R2-D2.  Asking wonderful things like "do you know about the R2-D2 Builder's Club? (yes)  And then L3-G0 would beep and they'd go "oh, he makes sound too!"  When they started to turn away I'd drive him out and run around the show floor and they'd say "No way, he moves?!?!?!"

L3-G0 was supposed to get set up yesterday, but the skirt took too long to get behaving.  I blogged about what he looked like yesterday morning.  That required 3D printing some bricks and stuff, but I still had time.  Unfortunately the skirt's on the bottom, so he had to be upside down with the legs & feet off to work on the skirt. 

 

When I flipped him back over and stuck on the remaining parts I found little things like the dome wouldn't fit: 

• Above the shoulders, I'd fixed a gap that was missing last time, he hadn't had that before, so I didn't know it'd cause clearance issues. Because of the tightness I'd left out a plate of thickness, about 1/8" and forgot it'd make the sides 1/8" too narrow.
• The left battery box hadn't been Kragle'd and tried to disassemble itself when sticking it on.
• Worst, somehow I'd messed up the center caster.  I knew the standards 3" caster didn't fit in my Lego shell, but my custom casters failed miserably.  But in the trials I found a 3" caster that seemed to work well.  I was so fixated on the fore-aft clearance I forgot about sideways, so he couldn't go backwards without the caster jamming or slamming the box to pieces.  So I gave up on Thursday.  Show didn't open 'til Friday @ 10 so I had time.  I used an early prototype and finally got his feet behaving around midnight.

Getting to the convention center was tricky.  His tie-down is actually really trivial in the minivan.  Jam the front casters into the hold-down for the far back seat (after taking out the seat) and throwing a bungee around it.  Then, with the dome off (sitting on the rear seat), stick the way-back seatbelts around the center post and let them click into being tight.  I'm used to Lego MOCs being fragile and insecure, but L3-G0 travels unbelievably well.

 

Of course that's before putting the fragile shell on it.  I thought I could lift it up, but it turned out there wasn't enough room for the bungee, so the shell came off.  That wasn't too hard, but I outsmarted myself and it was harder to put back on than I'd expected once I got to the convention center.

Once there, the fans loved him.  One seems to have found the droid they were looking for!

 



L3-G0 worked really well.  On the previous trials parts fell off and there were other small problems, like when the shoulder broke.  But he was really reliable.  Unfortunately the battery died before lunch, and I let it get really low, so it wouldn't fast-charge.  Fortunately I found a motorcycle shop that had another.  Alternating two seemed to work fine later in the day (though it's annoying to swap), but we'll see tomorrow. 

 

The worst part was the prodding of the fans.  They liked to poke.  And many wanted pictures with their hand resting on the top of his head.  Which is the most fragile part, so his head was dented a few times.  And he had an accident with his front foot, but for the most part L3-G0 was strong and ran well.

 

At the end of the day the sprockets on the bolts I'm using for axles started slipping :(  The best I can do is probably tighten the set screws in the morning and cross my fingers, but I think it'll be OK.  And maybe slow down the acceleration curve a bit.  It looks like the rest of the stuff I did to tighten up the wheels worked OK though, so it should be solvable.

 

Gotta get over to the R2-D2 Builder's Club folks sometime, which should be tricky as they're in the other building, and worse, on the other side of the trade floor.  The alternate route crosses the street and L3-G0 hates pavement (way, way, way too bumpy).

 

Need sleep, two nights up way too late.

Sealug Meeting

L3-G0's not done yet, but he's getting there!  We went on a test run to the Sealug meeting, which was held at ECCC's headquarters.  The kids loved chasing around a life size R2-D2 and were willing to look past his partially completed state.

He's obviously missing his legs/shoulders, skirt, front foot skin and a few other details, but I wanted to test transporting him and see what problems I might encounter, and where he might fall to pieces.  I don't want to be spending all of Emerald City Comicon fixing him!  Sounds are also still on a random loop, and he has no dome LEDs at the moment (which means he can spin his head a ton).

I have some video of his outing, the meeting starts about 40 seconds into the clip.  I took a week off work to make a big push to get him from frame to nearly complete:


I didn't think I was going to get the dome reattached before the meeting, but Lara prodded me and it was mostly reconnected just in time (I was a few minutes late).

The test outing was a great success, we learned tons that we'll need to know for ECCC later in the month:

• He does great with his new shoulders in the car.  Tying down's going to be tricky when the front foot cover gets on, but otherwise much more stable than when I took the frame to work.
• The new shoulders (laminated plywood) seem to be doing OK.  Since he has 4 wheels in each foot, there's a lot of stress when he turns because some of the wheels have to slip.  That pretty much destroyed the old thinner shoulder hub.  I'd expected to need aluminum, but the plywood's doing OK.
• On a related note, when turning hard, the feet can chatter a lot, enough to knock off the battery box (at 60 seconds in the clip one of them is missing).  The outer foot panels chatter too.
• He can spin his head fast enough to throw off a holoprojector, which happens at about 1:20 in the video.
• With the throttle limit off on the motors he has pretty much a perfect amount of power, much faster than walking, but not so quick as to be uncontrollable or unrealistic.  (My previous outing was limiting the motor controllers and he was just under walking speed).
• He looks funny without shoulders :)
• The vibration from pavement or even a sidewalk is a bit scary, he knocked a couple dome panels loose that way.
• The body held up really well.
• L3-G0 knew to expect rain in Seattle, but it started to snow at the end!

We still have a ton to do before ECCC, crossing my fingers that we can get it all done!  L3-G0 will be in "Brick Nation" at ECCC, the biggest Lego display yet at Emerald City Comicon.  Ground floor of The Conference Center building.

Starting to get back together

Update for my L3-G0 build, the full size Lego R2-D2.

It's like cleaning where things get worse before they get better.  Finally he's starting to get back together WITH his frame!

He was upside down a bit while I tried to figure out the skirt (built back on "Day 3", but haven't had anything to attach it to until now.... and now it's not right :(

 

And unfortunately the shim that the dome's bearing is on didn't fit once the body was bolted together.  The original shim was hand cut, but now the body is in a laser cut 12-sided shape.  Apparently without a frame it had more play.

 

Even worse, the (@*&#()*%& bearing didn't come with properly spaced holes, so I had to get at the bearing to transfer the bolt holes correctly.  And the bearing was on the bottom of the dome.  I almost got away with having the dome upside down, but it didn't survive :(



I'm hoping to get the dome back together for the Sealug meeting tomorrow, but it might not happen.  He obviously isn't complete, but I'm hoping to see how well he transports.  I'd rather mess up tomorrow with weeks to fix it than mess up on the way to Emerald City Comicon and have a few hours to fix it!.

Brickcon 2013 L3-G0 Setup

L3-G0 Made it to Brickcon!!!

Whew, that was way more complicated that I expected.  Especially since the new! lights blew up at 1:30 AM. 

But he made it, here's a quick clip of L3-G0 doing his thing and some of the other MOCs at Brickcon 2013 (Oct 6/7).

 

Robotics

Right now L3-G0 is using FOUR computers:

 

• Perhaps counterintuitively, a Lego EV3 Mindstorms to make his head spin
• An Arduino for the blinking lights.
• A Microsoft Surface for the sound effects (looping audio track)
• And a Surface Pro that programmed the Arduino and the EV3, at the moment needed to trigger the EV3 (start button's buried), and was using it to tune the dome program for the conference today and tomorrow.

L3-G0 is Ready for Brickcon!

Yippee!  All ready for Brickcon 2013 (October 5-6 at the Seattle Center)  He's not going to have feet at Brickcon because that's going to be another very huge undertaking.

 

I didn't have a ton of time to post, so a lot happened.  The dome sits on a bearing, so that had to be mounted and bolted on.  The dome also basically fell apart and had to be rebuilt... better... stronger... faster... (yes faster, and it didn't even cost me Six Million Dollars).

 

Nikita helped test the dome:



 

The bearing and dome base rest on a support that is made from the hinges that hold the panels together.  There are two motors for the Lego EV3 Mindstorms (this is the largest Mindstorms robot I've built by far).  Two because they push a lot better than they pull.  The wheels will rest on the inside of the bearing, attached to the dome of L3-G0.  On the right, near L3-G0's blue front you can see a color/light sensor.  The light sensor is used so the EV3 knows when he's facing forward.

 



And here it is with the dome base on.  You can see that the plates on the base of the dome ring are bolted to the aluminum bearing.  The bearing has a plastic support ring on top of it, also to keep it from dragging the dome bottom on the static side of the bearing.

 

The bottom of the bearing is mounted to 1/4" plywood, seen here from inside the body, before the dome ring was installed on top. 

 

 The dome itself has been strengthened, and stays together much better now.

 

Also finally got the shoulders finished.  Lots of bits weren't perfectly aligned in the Lego Digital Designer (LDD), and LDD also doesn't show you how to attach 12 pieces from different directions at the same time!  Getting everything to snap together right was a bit challenging.



I like the detail on the shoulders, and also I like the "Under Shoulder Detail" (R2 Builders Club Lingo):

 

Timelapse Video on YouTube

 

I show his dome spinning at the end.  I'll have a better video of that later, but here's what I have so far:

Building the 2nd Dome Panel Row

Hosik, a Korean foreign exchange student helped out this time, thanks Hosik!



Hosik and Darius also helped make sure the cat (devil cat?) got some cameos.

It's sort-of days 11-12. Sort of because sometimes I only get an hour or two, so I try to get those into a "day" unit, whatever that is. This part of the dome's being really hard because of the multiple curves. At least the plan is mostly working, however the incomplete sections are fairly fragile. I also took time to build up some plates where the dome will rest on the Lazy Suzan bearing. Since the dome was already partially built, I did that from the bottom.

Also got the eye done!  The eye was challenging because the shapes don't align very well to actual brick sizes and shapes.

 

The logic display also looks particularly nice with a flashlight behind it.  This was fairly challenging to get all of the panels to fit next to each other and provide enough structure for the panels above and below.  It was rebuilt several times.

 

Its starting to get there.  I'm so focused on the detail that I miss the big picture sometimes.  A few times L3-G0's gotten my skin crawling when I walk into the room after stepping away.  Then it's like "who put that R2-D2 in my kitchen?"



Time Lapse Video for the Middle Dome Layer

 

Filling Holes

Yippee, most of the rest of the bricks arrived (there are still a couple where we were short for various reasons, but that won't stop us).

So this post is "filling holes" in the parts we already built, along with some better photos once the right parts are in place

First I added the little gray ring on the tippy top of the dome, only one brick, but a pretty big detail

 

Next was filling in mostly the missing tiles on the body.  Some of the white tiles for the panel outlines were missing, as well as tiles on the vents and some of the coin return slopes.

 

Detail of the side vent, notice that the blue parts are recessed.

The quarter of the body that fits together so far (3 other panels are done, but they're the same or mirrors of these and don't directly connect).

 



Next, the legs.  I really like the detail on the leg strut and it's angled square top.  Also the complex curves where the notches are, and at the top of the booster cover under where the shoulder hub will go.  We were missing the little slope parts and some tiles to make this all work.

 

Top of strut in booster cover:

Notches recessed in a curve in the booster cover:

 

Complex curves at the top of the booster cover:

The center foot was also missing a couple square plates on one side, but the photo isn't really different than before, so I didn't include it.  Also the side "footprints" were also missing square plates, but they're not very far along, so I'll photograph them when I do the rest.

 

Lastly, I fixed the colors around the bottom edge of the Holoprojectors and removed the shim plates, so they look a lot better:

Next up is probably more of the body, probably starting with the rest of the back since the two remaining back panels would allow me to connect 8 of the 12 body panels.

Time lapse of filling holes and the resulting parts

Building on Day 4 - Starting the Body!

The parts we needed for the body arrived!!!  We're still waiting on ~1500 of the original ordered parts (a little bit of rework has caused us to order a little more since then).  So there're still some gaps for parts.  Considering it's 15K+ parts, we've done great missing 10% of the bricks!

The body is 12 panels, and I started on six of the easiest.  Mostly because they're either identical pairs or mirrors.  So that's about half of the body!  (just the easy half).  3 of them are contiguous, the next two holes in this photo need an additional panel, and the last two go next to each other (despite the gap in the photo).  You can see the missing bricks :(

 



Three are next to each other, so we can see how they fit.  If you can get over the missing bricks, you can get an idea of the 3-D detail.  I'll probably take some close ups when we get the other bricks filled in.

And an idea of the scale, Lara posing with the partial body.

 

Time lapse video for day 4

(All 3 cats interrupted the video, they like playing with the loose bricks.  Additionally there's.... horses?)

Building Session Three

Well, something about having to work, so I didn't get daily updates.  Instead the bits are interrupted and built over a few days.

We still don't have all of the parts, so there's a few holes to fill in the results, but there's a good start on the skirt (under the body), the very top of the dome (I thought I had all the parts, but it's missing a little gray ring), and the legs.

Worked on the skirt first (daughter realized it's his butt, what do you expect from a teenager?)  Unfortunately we're missing a bunch of the "wing" pieces to round out the edges :(

It's also a bit "wobbly" because the hinges let it bend, but that'll get fixed later.  Even so, I think it's looking pretty good.  (Photos are with the skirt upside down).



I thought I had all of the parts for the tippy top of the dome (above the pie plates), so I figured I'd whip that out in about 10 seconds.  Unfortunately I'm still waiting for a little ring on the very top.  (Hopefully tomorrow).  I was able to use the flying saucer or whatever they're called parts for this part of the dome.  The angles and sizes matched surprisingly well for that.

More successfully I worked on the legs.  Again, some parts are missing, but I got further, including some complicated stuff.  Obviously they're incomplete, but I'm reasonably happy with the detail.

 

One thing I realized looking at a photo of a real R2 is that my legs seem a bit tall.  I was expecting them to attach to the plate on top of the ankle, but the distance between the notch and the bottom seems longer than on the real photo.

 

Coincidentally, the R2 builders group had a thread today that mentioned "standard" and "extended" legs.  I wonder if I followed plans for "extended"?  Clearly there's some measuring in my future to make sure I get them the right height.

 

Top is missing some of the slopes to make the recess rounded (it's a pretty complex curve), but here's the top so far.  Hopefully the slopes come today:

Time Lapse of Phase 3 Building:

On to Day 2...

Day 2 building L3-G0.  Mostly finished the center foot, except a few parts are missing (still on order), which is part of why the corner edges don't fit as nice as they eventually will. 

Also the center ankle cylinders (back one's also missing some parts).  And a tiny bit of the dome, which was missing a lot of parts so I decided to come back to that later.  The dome edge will need a little rework, and it's got me wondering a bit about how I'm going to fit it to my bearing.

There's a Day 2 Time Lapse Video too...



We've got brick!!!!!!!!!!!

We've got brick!!!!!!!!!!!  The mailman's a bit impressed.  This is JUST ONE DAY's delivery, only 18 packages of 52.

And when you get bricks, you have to sort :(  Thanks Jaron for the sorting boxes!

 

As of today we have enough to start building, but we're still waiting on 6 packages, so available parts will guide what we start building with.

 

Also a few packages were short a couple bricks (we're still above 99.9% accuracy, but when you order 13 thousand bricks I guess a few are going to be short).  So I've updated the parts needed list if you have a few bricks in great shape to spare.

Other Lego MOCs

I wanted this to be all about L3-G0, however it occurs to me that its not easy to find out about our other MOCs, so here are some links.

* http://ourrandombits.blogspot.com/ - Disorganized posts including other Lego MOCs
* http://www.youtube.com/shawnlara - Disorganized YouTube channel with MOCs (don't tell google that you clicked on the ads for me).

Our Lego Space Needle:

http://ourrandombits.blogspot.com/2013/03/the-space-needle-was-destroyed-again.html
http://youtu.be/TIX5zC-na1A

Our Lego Disney Wonder Cruise Ship:

(Cool story)
http://ourrandombits.blogspot.com/2012/12/LegoWonderCruiseShipPage1.html
http://youtu.be/npljfpINL70

Thanks for helping!

Thanks to the Bricklink sellers I got parts from, ordering ten thousand parts is tough!  Special thanks for these sellers for helping with discounts.  My costs are still unmanageable, but every bit helps!

• SuperBrick
• Dhavilan Emporium
• Dumbos Mother
• The Brickhouse
• Free Shipping Deals
• HouseOfLogos
• Amazing Bricks

Also thanks to those that provided some bricks:

• JR Tyner
• Laurel Lee
• Merelee Knott
• Bernie

(There's a list of tough bricks still if you want to help).

Thanks to Jaron Kelley from SEALUG or providing sorting boxes!!!

Thanks for Helping!

Thanks to everyone I got parts and other help from.

The following Bricklink sellers helped, ordering ten thousand parts is tough!  Special thanks for these sellers for helping with discounts.  My costs are still unmanageable, but every bit helps!

• SuperBrick
• Dhavilan Emporium
• Dumbos Mother
• The Brickhouse
• Free Shipping Deals
• HouseOfLogos
• Amazing Bricks

Also thanks to those that provided some bricks:

• JR Tyner
• Laurel Lee
• Merelee Knott
• Bernie

Thanks to Jaron Kelley from SEALUG or providing sorting boxes!!!

L3-G0, the full size Lego R2-D2.

We've made a few Lego models, such as the Lego Disney Wonder cruise ship and a Lego Space Needle, and it's about time to do something new, but all of our ideas were pretty lame.  So in the back of our minds there was some thinking about "what could we build next?" 

Then we went to Emerald City Comicon and saw some of the wonderful Astromechs there.  Of course I wanted to build one, but quickly realized it'd be a ton of effort, cost a lot, and I wasn't terribly familiar with the materials.

It should've been obvious, but "gee, I wanna build a droid" sat in one part of my brain while "I wonder what I'll build next in Lego" sat in another part.  Eventually we came to the obvious conclusion:  "I'll build an L3-G0".  Don't know why it took so long.

Normally I grab a bunch of bricks and start building, then get more bricks, but for various reasons I started toying around with some of the sections in Lego Digital Designer to see if some of my ideas were practical.  Of course, once I started, I forgot to stop.

Now we have a 15,000 piece model pretty much figured out, and all we need are about 12K more bricks!  (Well, and some sort of frame, and some motors, and some electronics).  We're hoping that at least part of L3-G0 will be done for BrickCon in October.  Feel free to send us your spare bricks ;-)

There are some parts that will undoubtedly need changed from the LDD model, and he's going to need an internal frame of aluminum or wood or something, but it should be do-able.

A couple more screenshots of the drawing:

The model is based on plans from the R2-D2 Builder's Club (Astromech.net)  Of course brick isn't as finely detailed as manufactured parts, but he should be "pretty close" to spec.  He'll probably be about 100 pounds.  Eventually we'd like more functionality, but for a start we're looking at getting him to move and beep in time for Emerald City Comicon (ECCC) 2014.  We'd love to take him other places too, anyone know how to get him to Celebration in one piece?

We'll post more as the project goes.

Bricks acquired so far:  15900/16000.