How To Build An R2-D2 – Page 11 – How to make an R2-D2 from scratch.

May 3, 2015March 31, 2017

Wooden Rear Logic Display Surround Pt. 2

In the previous post, I discussed how to cut the circular portion of the Wooden Rear Logic Display Surround. In this part, I will go over cutting the rounded block into two halves and the side portions so the surround can be mounted. This is not the easiest thing to do and practice will help, not all pieces will come out looking perfectly so you may have to give it a couple of tries until it comes out right.Watch Full Movie Online Streaming Online and Download

I will be using my ruler, miter saw, and some double stick tape to accomplish these not so easy cuts.

Lets start by cutting bevels of the long sides and short sides. Using the plan for the Rear Logic Display, I marked my piece to give me enough room to cut the bevel to its total length and give the raised portion of the surround its overall thickness. I used the remaining board and double stick tape to secure the block and hold it in place for cutting. The bevel is 12° and the miter is 22°. We do this two times for both halves of the long side.

We do the short side in a similar manner, except the block is a thicker piece of wood, the bevel is cut to 31°, and the miter is 23°. These four pieces are glued together to complete the inside portion that is raised above.

I used a similar method to to cut the outside portion that will be used to hold the raised portion to the inside of the dome. This will be glued to the outside.

Outside Logic Surround — Outside Rear Logic Display Surround

April 8, 2015March 11, 2016

Wooden Rear Logic Display Surround Pt. 1

The Rear Logic Display Surround hosts the Rear Logic Display on the back of R2. This one was made similar to the way I made the Front Logic Display Surrounds. The difference is that this piece is rounded and needs to be cut and measured very carefully so everything comes out correctly. The materials used is a piece of poplar hobby wood and some double sided tape. I used a plunge router to cut the curve and a miter saw to cut the bevel and miter. To do all the measurements, I used my ruler and rafter square.

The first step I took was cutting the circular portion of the surround. I made a plastic circle cutting guide for my plunge router to cut the 9.125″ radius circle. I then made a hole in a piece of poplar down the center of the board 9.5″ from the top and secured the board to a table and cut the circle.

Wooden Rear Logic Display Surround — Cutting the round section of the Rear Logic Display Surround

Final Cut of the Rear Logic Display Surround

I then marked my board, from the top center of the circle going down, the total height of the piece. Another line was marked perpendicular to that line so I can cut that piece off the board. Once cut off the board, this piece will be used to make two halves of the surround.

The next post in this series will go over cutting this round section into two halves with proper dimensions.

January 9, 2015March 11, 2016

Wooden Logic Display Surrounds Pt. 3

Once all parts are cut, we need to glue them together. I used the panel from the outer dome as a guide to test the fit of the wood pieces. After verifying the fit, I took some wood glue and put it on each side of the wood pieces and assembled them in the panel. After one hour, they were dry and awaiting a bit more cutting.

Gluing pieces — Gluing each piece of the surrounds.

Panel as guide — Using the panel as a guide and frame.

After the glue is dry, we take the piece out of the panel carefully so we don’t bend the panel. The panel is made of Aluminum so it can bend easy. The outside area is then cut to fit the inside of the panel per the plan.

This is a quick video of the whole process for cutting and constructing the wooden logic display surrounds.