My R2-D2 Build: Feet

This section show the build process for R2-D2's feet.R2-D2's feet are comprised of 3 major parts. The motor holders, the foot shells, and the battery boxes.

Battery Boxes

I started with a lot of clamps and used Ambroid ProWeld to glue most of the parts.

The first pieces are glued together.

Then the glued pieces are clamped to each end of the oval back piece. This is NOT glued, it is just to make sure things line up properly.

Now the front piece is glued to the top of the end pieces.

I used the piece that is going to be bent around the curve to mark where is would end up after it was in place.

The main cover is placed in between the marks.

Some scrap pieces from the foot shells are used to reinforce the joint and glue is put across the length of the entire seam.

Repeat the same steps for the other side.

Before the piece that goes on the curve can be glued the edge needs to be removed.

The incomplete battery box is temporarilly placed on the foot shell and marked for the opening to accept the motor.

The hole for the motor is marked and then cut out.

A scrap piece of plastic from the main body skins is used to make a tab along the piece that is going to be curved.

The tab is placed on top of the inside of the main cover and glued in place.

Another tab is glued in place on the other end of the curved piece. The corner of the tab is clipped on each side to make it easier to tuck under the main cover.

The piece is tucked under and glued in. The process is repeated for the other end.

Here is a picture of the nearly completed battery box attached to a foot shell.

And the scooter motor holder inside of the foot shell.

This is the center foot shell. I still have a couple of detail pieces I want to add.

This picture shows the view of the scooter motor holders from underneath. Here you can see the tire on the right, the motor in the middle, and the ball caster on the left.