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

 

Front Vents and Dome Ring

The last few days were complicated.

Saturday I took the body to the SEALUG meeting (Seattle Lego Users Group), and it fell apart in the car when I braked for a stop sign. Internally there's some hidden hinges that didn't really have a ton of surface area.  We cleaned up some to make the body sturdier. Now the hinges connect to the body panels with nearly 3 times the surface area. It might still need some glue to be motorized, but it should at least not fall apart.

The front vents weren't done earlier because the hole in the front panel needed to move a little from the original plans. Additionally, LDD let us have some error in the brick attachments that didn't work in the real world.  It took quite a bit of effort to get the panels securely attached. At one point there was a quarter-plate difference in height between the vents and the hole to attach them. I have no clue how to move something 1/4 plate, and it was too loose as it was. I fixed it by making the middle blue stripe slightly wider, it was a single stud (2.5 plates), now it's 3 plates. I also noticed a few missing outline tiles.

 

We also started on the dome ring, which was tricky because the original design had some pretty big flaws. (Lego Digital Designer doesn't really tell you if stuff is structural or not).  The ring portion is complicated because the middle bricks of each section are offset by 1/2 stud to help the illusion of being round.  Complicating matters are a couple slits that go the circumference of the dome, which we did by recessing the plates there by another 1/2 stud.  It took a little work to get everything secure

Time Lapse Youtube Video

The horses get to go on a carousel ride.

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

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.