Progress on Booster Rocket parts

Here you can see some actual pics of the Ali Booster Rocket parts:

Last parts printing

For my little fellow D-O i am actually printing parts to finalize the build.

In the background are the last parts, in the foreground you can see some detail parts for the Aluminium Booster Rocket Sets, that are actually in their building process.

Progress on the D-O Parts mixture assembly

Having parts in 3d from several downloading times from david's thingiverse page,  i am totally confused now in assembling the parts.
Some fit perfect, some not.
Some.needed to be printed again, some are still missing. Unfortunately david's page is covered now, so now you have to donate money to him.
Pretty fair, but those first version parts were for free.
Now i have to see, what i can do...
My son will help me with the CAD work on the parts hopefully.

Here is an actual picture of the Droid:

Color change

The D-O Droid parts are getting a new color.
Red is Out, White is in!

Here the Center wheel parts..

Pic will follow

And the still missing cable holder

Pic will follow

Some rods were reprinted too...

Pic will follow

Booster Kit...First Ali parts

 First Ali parts are in the cnc'ing process...

D-O parts

Removing all Filament remains from the 3d printed parts ist a time taking job, but it has to be done.

Some 3d printed parts will be replaced by Aluminium parts (rods).

Aluminium Booster KIt

from a dream to reality!

i always wanted to have that booster kit, but the price for it was way too high for me. the guys over the pond wanted to have more than 900 Dollars for it. plus shipping costs, plus tax and other fees here. in the end it would have been more than 1100 euros until they would be here.
no way!

so the decision was made to let them produce here. i don´t like to send them to china to get them made for almost nothing, i wanted to keep the work and craftmanship here in germany.

my buddy at the cnc shop found some time for me to do a small bunch for me, after another buddy changed the stl files back to stp files. not an easy work, but he made it in the end! great work!

this morning we discussed the last problems and this afternoon he could already give me a price for all parts.

now its up to me see who is in need for a set oooster boxes... 

Aluminium Booster Kit...a Dream ???

yesterday my cnc buddy came across to check out the latest issues or ideas for the final cnc version of the parts for the booster kit.
making some details less detailed, but therefore realize them in another way. so we could reduce the time consuming process of milling.
maybe i get a prototype of it within the next two weeks or so...

A bunch of parts

I took some time to build some R2 parts for me and some good friends

Here are some pics to that:

The first HD Battery Box is done now. On the table the sheets for number two.
The thickness ist 1,5 mm.
Here the first one freshly primered. Looking quite dark, but it will be lighter in appearance when dried out.

As you can see here: In the foreground the second HD box:

 the next set was a little bit easier to built, because it was 33% thinner in thickness.

Second ali super lightweight leg

one ali lightweight leg was already built a year or more ago.



then my welding machine made some problems. or it was me doing the wrong steps, adjusting something wrong on it, using oxidated aluminium...i don´t know yet what the real problem is...

Pic will follow

i talked to my buddy at the metal shop, he gave me some advices now...

let´s see how it turns out...

because i want to get the second leg done finally!

Lightweight steel battery boxes

the last one of the four battery boxes is built now. here the second set, ready to be media blasted and primered in light grey:

pic will follow

the more boxes i build, the easier they are to handle. working steps seem to be easier, there is a sort of automatism in it now.

Problems

i don´t know why, but the printer refused to print the second booster itself the correct way.
it stopped at one point and then it was thrown down onto the printerbed by the nozzle.
curious!

so redo the booster is on the agenda!

the next problem;
the files from the booster kit are stl, so i must try to transform them into step files. easy said, complicated done. because the information given to the 3d printer are completely different to the ones a cnc mill needs.

i contacted my buddy at the cnc shop to see what he can do for me... more on that later the next days...

Second set

the second set of the booster kit is about to be finished soon.

can´t wait to assemble everything and get a servo for the booster movement mounted in the ali leg...

by the way; time to build the second ali leg now. therefore i need to have a look for the welding machine, that was making problems while ali welding last time...was it only an oxidation problem?

who knows...?

Booster Print parts

Everything went fine until now:

On to the next parts for the other leg!!

Another set of battery boxes

And here we go...building the first of four battery boxes...

Help from Holland

David could help me with his files to get a better understanding where all the parts have to be on the tiny Droid.

Now it's up to me remove all rests of printing remains that are not necessary.

The rods will be replaced by real metal. In this case aluminium tubes.
So off to the metal shop!!

Booster Kit

i always wanted to have the booster kit on my ali droid. one of the few parts that are missing in aluminium.
unfortunately i couldn´t get the files from jerry, who made these years ago.

now i found a guy in australia who made these parts in .stl format. this means, they can be printed with a 3d printer.
i downloaded the files now and will soon start to print the first parts for it...

meanwhile i will give these files to my brother, who can change them into a format to get them machined from aluminium. let´s see, what he can do for me.

ali is the better PLA !! LOL

Questions over questions

i printed a lot of parts now for the d-o droid yesterday...

some of them are logical in their function, some are not.

are they for a static droid or for a fully movable and radio controlled unit??

Maybe David from the Netherlands can help. He made the files...

I contacted him yesterday and he will answer my questions this evening...hopefully...

New PLA filament

Just received a box full of white filament.
We can continue our prints...