One done, one more to go!!

the first ali battery box is ready!

Bending and welding

Day two of the ali battery boxes building process.

after bending the first sheet around a tubing (not that easy with 2 mm ali!!) and the second part to get the "steps" into it, welded the backward plate into it and grinded it with 40 grit.

next step is to fix the front plate to the box and weld it on too!

Ali battery boxes

Time to build a set of CS:L Ali battery boxes.

First results

building the silicon mould was a challenge, getting the very thin resin part out of the mould another.

the result was a too thin part, warping and cracking too easy. :(

here you can see it laying on top of the leg:

cutting it into two pieces...

the part didn´t satisfy me! super light, cool, but really too thin. and too much work to redo it. adding more resin from inside, repairing the cracks and the warping of the parts... hmmm  a lot of work too.

now i have to figure out, which way of opening system is the best.
this one?

or the jag style?

The Blog

talking about this blog;
ok, the name is "der deutsche r2 blog". this means, it is a german r2 blog. but thinking to write everything in german would be fine, is a fatal mistake!
most of my visitors are not from germany, no, they are from all around the world. so the mostly used language is of course english. that´s why i decided to post everything here in english. i might do it in french or spanish, in dutch or german too, but this would be too much work for me!! ;)
so i keep it in english. if you are not that familiar with this language, please use the google translator or any other translation program.
happy building !!!
PSN

Espanol

Hola mis amigos españoles R2 Builder !!
Gracias por visitar mi blog en el que.
Estoy feliz de ayudarle en la realización de sus astromecánicos.
Para preguntas acerca de las piezas que se muestran aquí se puede ponerse en contacto conmigo.
Esto va más allá de los comentarios. Los comentarios deben primero ser desbloqueados por mí y no son visibles para los demás.
Como alternativa, puede enviar un correo electrónico a la siguiente dirección: notchback64@web.de
saludos cordiales
Prostreetnotch (PSN)

Customs

today i had to drive to the customs. its a 25 minutes drive...boring, a lot of traffic, bad wheather.
but everything was fine after i received (and paid the tax for) the ali radar eye from granite earth!

great stuff!

Difficult

Getting the Silicon and the resin part out of the mould was horrible!
But I made it!
I added some more resin on some Spots and will have to spent some additional time in it, but for the first attempt it's looking good!
But today is outer feet building time, so the resin Booster Cover has to wait!

Page Update

i just updated my other r2 related page...visit it under:

www.prostreetnotch.jimdo.com

Diet Ali Ankle Details

my preferred cnc shop made some new parts for me...

the same as in my previous runs. just plug and play!! :)

So tricky !!

doing such thin walls on a mould was a challenge.
air bubbles remained in the resin. i already opened the mould halves and saw areas, that had no resin in it. so redoing it was the plan.

having it done now, i wanted to get the the silicone inner mould out of the woodden frame. almost impossible.
i have to try something else... :(

Ready, steady, go!!

Today was building time! Building a Center Ankle for a good friend's r2 unit, then building the mould and put some Silicon plus the part into it. Here is the result:

Next step is to prepare the two moulds to get a resin cast of it.

First mould

I got the woodden sheets from my neighbor, the carpenter.
But the very first thing I made, was to prepare the Ali Booster Cover. Closing Thread holes, closing openings, modify the Booster Cover with an Air powered Tool.
Then adding Silicon into the cover...

Next step is to build the woodden mould.

Mould building

Yesterday my neighbour the carpenter had no time to cut the woodden sheets for me, but today it might work.
So when the the frame has been built, i can put the booster cover into it.
I have to do two steps; fabricating an inside and outside mould piece. Plus outlet channels to avoid remaining air bubbles in it.

Mould Frame

taking all the lego bricks from my son isn´t the best idea. i decided to get some woodden sheets from my neighbor, the carpenter.
some screws, some minutes of work and the basic frame is done!
if my neighbor would be there! a few minutes ago, he and his brother were still in their business, now it´s closed.
let´s have a look, when they will return... :(

Arrival

the silicone stuff has arrived now one day earlier than announced.
crazy!!

Delivery Delay

The silicone shop sent me a mail yesterday, that the ordered material hasen't been produced yet and there would be a delay until the 10th to14th of this month
But the very same day, only two hours later, i got the annucement via ebay, that it has been sent...
Aah yes, i see....!!!
Now it should come on Thursday...
Surprise surprise!!

Silicon Stuff or "The Real Booster Cover"

i ordererd some new silicon to make a big mold for my "real booster cover". i hope to get it in the next days.

then i will "borrow" some lego bricks from my son to build a huge mold for the ultralight resin booster cover.

more pics and infos on that later!

The Postman always rings twice !!

last week i ordered one of the last parts for my ali r2; the radar eye. a little bit more expensive than expected (too high shipping rates!!), but i simply wanted to have it!! :)

i already had the dome drive and the dome drive bracket for my ali r2. but an interesting offer made me change my mind.
next week i´ll gonna get a gearless version from my buddy ricardo.

so pics of the radar eye and the dome drive in a few days!!

Mando Costume

I've been doing from time to time some work on the mando costume for my son. Rogue One is coming soon on cinema, so the first troop of his life is the reason to get it finished right in time!
Here are some pics of the unfinished costume:

New plans for "Real" Booster Cover

I will make a new silicon mould of the Ali booster cover.
Then there will be made several cuts in the ultralight resin parts, that i will get out of it.
The target is to get them open and/or sliding into the legs openings of my steel (and soon) Ali version lightweight legs.
Due to massive work in my enterprise and preparations for a small new series of my wellknown diet Ali ankle details there will be some time passing by!
As well i am working on the Princess Amidala costume for my daughter.
The Jyn Erso costume for her is "on ice". Too much details and not enough time to get it finished until mid December!!