R5’s Bad Motivator : reincarnation (Part 3)

As mentioned in my previous post, Monday saw me start on drawing/creating the ‘Bad Motivator’ as i saw it in the movie, screen grab. See below.

There are some features that I can now see that I didn’t before, and these have already been captured by other already created designs. So these I’ve incorporated into my design as I believe them to be correct in my opinion, and scaled the other parts to better match (again, how I saw/see them) into my design.

The first design I wasn’t 100% happy with so altered it for version 2. I was going to print each component separately, but couldn’t be bothered lol, plus the combined part’s secured the motivator better as one. This would be great as a resin printed piece, but for now I’ll have to make do with my printer lol.

3D coloured rendering of new motivator.

I uploaded the file to Astroprint so that I could print out at home on my Tevo Tarantula. The printer is running already, hopefully this will be done by the morning.

(Astroprint is a free online program to convert stl files into gcodes for your chosen 3D printer)

13hrs later…… the print came out great 👍🏽

Wasn’t happy about the size/scale though so going to edit and reprint.

*** January 2025: link here added to the3D printable file ***

R5’s Bad Motivator : reincarnation (Part 2)

March 2022

Planning out the electronics/electrical connections etc.

This has been the most concentrated effort of work to get things ready for Birmingham's event @MegaCONlive [26th March 2022].

….well…..I got it working on the bench, but there was a problem once installed in R5’s dome.

The smoke system worked ✅

But the magnetic actuator didn’t have enough to move the motivator assembly ❌

So back to the drawing board & a new lighter motivator assembly .........

October 2022

I eventually returned to this project as have time. I thought I’d try out an idea that Brad 'BHD' had a few years ago to activate HIS bad motivator’s on his droids.

It utilised a servo, pivot arm and a track system. His droids are gone, but his webpage Blog is still lives on 😎👍🏽

Link: Brad’s R2-X2 Droid build

For lightness I dug out a rail and bearing carriage I'd salvaged from a 3D printer.

Next up was to measure the carriage’s holes position, so that I could draw up in Inventor CAD, an adapter to a-fix to it for the Bad Motivator. I then needed a bracket to secure the servo to and also the rail. So again I CAD’ed up a design and 3D printed it off. It was a Friday, so I knew that this would have to be ‘modified’ lol. Sure enough, with the help of my soldering iron, (melting plastic to reshape areas, the servo fitted into place.

I’m using a metal gear servo for strength, the new motivator isn’t overly heavy, but just to be safe as it will see a lot of action.

As this setup is in R5’s dome, my standard arrangement to activate the bad motivator, is via a remote control fob.

I have been toying with and have tested out using, one of the other transmitter’s receiver’s (I have a few spare and connected it up using the last free channel on my transmitter). This is still a work in progress idea.

After printing the components, I test fitted the assembly unit into R5’s dome, only to find that the rail was further over than existing setup. The new assembly is fitted inside the dome, the old one, resting on the top of it. the 'white' component is the original 'Bad Motivator' location piece, the inside 'black' component is the new 'BMs' location piece. So I had to do some CAD alterations.

The next set of prints worked much better, fit wise. On test fitting, I had trouble with the actual motivator fitting up through the pie hole, without it catching on the new rail. This was due to orientation.

I’ve always accepted this motivator design as (at the time) was the only version available. But I think its now time I stopped wrestling with that nagging feeling and CAD up the motivator ‘that I envisioned years ago when I first sketched it up from what/how I saw it from screen caps’. (Said in Moff Tarkin’s tone of voice 😂).

…….So that’s Mondays project!

Next was to install the brass inserts, drill a few holes to secure parts and wait for a dual relay switch to arrive.....

The Book of Boba Fett: R5-D4

*** SPOILER ALERT!!! ***

The Book of Boba Fett

*** DO NOT SCROLL DOWN ANY FURTHER *** 

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Sat down to watch Episode 5 of The Book of Boba Fett and was excited (as always) to see R5 in action 😍😍😍😍😍

Flicking between watching the scene and paying close attention to R5.... I was disappointed to notice continuity errors in his appearance 😞😞😞😞😞.

When R5 was re-introduced in The Mandalorian, session 2, there were the usual hype and details noted which could be explained away as 'over time this and that were fixed'. OK, so THIS version is the NEW version, that's cool.

Then in his latest appearance, I noticed a few details and ALL in the one scene!

The above images were captured, in time order in the scene he appears in.

1. shot, no motivator panel, no rear box red strips.
2. shot, motivator panel in place, red box strips.
3. shot, repeat 1st shot.
4. shot, repeat 2nd shot.

Now, either one of two things:

• The version with the motivator panel in place [which was seen in the behind the scenes documentary on Disney+] is the REAL remote controlled version.
• The version with no panel in place is either a repainted version [filmed at a different time] or is CGI.

Bad motivator actuation upgrade 1.2 (2019)

I did some design changes and re-printed off a new holder.

This one fitted much better all round. I had made slots in the inside top face , but I hadn't made them wide enough to allow the crimped edges to fit. Also the clearance hole in the top, didn't clear the shaft enough. It didn't need to be so close a fit.

Next I needed to add a new joining pivot piece similar to the previous one which came fitted on the door actuator itself.

Hopefully I’ll get time to test fit this. I’ve included a hole to fit a locking pin through.

Bad motivator actuation upgrade 1.1 (2019)

Drew up a holder in AutoCAD Inventor and printed off a sample.

This was slightly tighter than it should of been, on the inside faces,

so increased some of the dimensions to allow for a better fit.

Here's the CAD model images.

 New magnetic actuator holder

This new holder, is designed to fit onto the exsisting bracket.

If this works, then I may look at 3D printing this all as one piece.

But for testing and speed, it's just an add on for now.

Smoke system tutorial - Part 3 Assembly

Last year I was working on an upgrade to the bad motivator system, in that I replaced the e-cig atomiser with a small vape tank. The reason for it was that the atomiser wasn't really up to the task, current going through it and was only good for short burst's of smoke.

Using a vape tank is not my invention, so can't take credit, it just seemed the next step in how to best get more smoke. Also this is STILL on a budget!

Since posting up and sharing of my original set up & 3D collar (on my Thingiverse page) other's have asked about this set up. And I've seen similar collars appear on other  builds. Am happy to share what info I have & have also been asked if it would be ok of them to offer as a kit form to members over in the USA.

(credit given, thanks).

So here's was my latest upgrade:

This is the vape tank I bought.....it was actually the wrong one I was actually looking for, but it was late at night and think I clicked and bought by mistake. The one I wanted had the vent hole in the outside of the body....nevermind lol.

In the above picture:
'A' is where the inlet hole is, just above the thread.
'B' there are four grooves that cross, allowing air flow.

So in order for the collar to to fit and allow air flow, I had to modify my original idea into this version. This I've not posted up yet on my Thingiverse page.The new collar fits directly over the 'flat top 510 spring loaded connector. Which has slots in it. The collar's cut outs, lines up with the 510's slots to allow the air flow through to the vape inlet hole.

I had been working on the electronics etc on this set up, so it's still not put back together lol.
But here's a picture of the collar fitted onto the vape tank.

And how it would all be assembled.

This assembly diagram is missing the bracket, which can be seen in the previous picture. This would fit between the 510 flat top and the terminal connectors underneath.

3D Printed dual smoke bracket

Just posted up on Thingiverse my dual smoke bracket

that I drew up and printed off for testing, before Christmas.

Link also to the You Tube video I posted up of the e-cig unit's in action.

R5-D4 - Bad Motivator system upgrade 1.6

It's been a while since my last update, but I have been busy.

I've drilled and tapped the slide so that the 'motivator' can be bolted onto it. The 3D printed adaptor, just needs some silver or black paint to blend it in.

R5-D4's pop-up motivator

I did a test fire of the pop-up of the motivator and it actually got fired right out of the pie hole.....!! I caught it tho. May have to do a video for that lol.

Next up was sorting out the contacts for the e-cig smoke unit. I tried to disassemble it to connect up more thicker wire, but this proved a waste of time as the soldering just wouldn't take to the aluminium of the contact. So I ordered two new components that I hope I can work with and these will then sort this out. I'll just need to design and print off a bracket for this to locate inside the dome.

With all the 3D printed stuff for the motivator pop-up system, the electronics control board was looking a bit naff.... So I drew up a simple'ish board (picture below) that all the components could be fitted onto. I next drew up a bracket so that this could be fitted to the inside of R5's dome.

electronics control board

I designed raised pads for the screws used on the remote board & voltage regulator boards.
The digital readout's have a rear wall around the rectangular holes for a tight fit.
The two orange units are the time delay units, these are just tight fit's into place.

I later installed two status LED's along with a mini switch to help show power and 'power on'. The reason for these is that the board only 'lights-up' when in use and the switch helps if I need to actually turn the motivator system off. Am also waiting for a second digital volt meter, as I couldn't find a spare one in my electronics stash.

With the new board, I needed to also draw up a bracket to hold the smoke pump in place.
So I drew this up...

I made the internal diameters smaller so that they would grip the pump tightly.

Once I've installed the second digital readout, I can then arrange where this is all going to fit.

R5-D4 - Bad Motivator system upgrade 1.5

So it was back to re-designing the pivot arm and linkage points.

I first used a piece of cardboard to gauge the distance after I took photos of the gaps that the pivot arm would need to be extended by.

I then redrew these up in work on Inventor. I countersunk the nut so that it looked good lol, no other reason other than the length of the bolt. Both parts seen in picture one were then reprinted in 3D PLA filament.

Recessing the nut, just makes fitting easier. It's a push fit into the recess, so is help tight.

Next up is the electronics, electrical & the smoke system to be re-installed. This will be next week as this weekend I'll be at the NEC Birmingham.

R5-D4 - Bad Motivator system upgrade 1.4

After printing out the actuator bracket re-design, I found out that I actually had less space than I thought and that the rear of the actuator was interfering with the inside of the dome, so not allowing it to sit in it's needed position.

Next problem was that in order to achieve clearance, I needed extra height (see pic above). Unfortunately tho, the longer version was TOO long (or high) for my mini desktop 3D printer.

So I had a thought and swapped the actuator bracket's location to the other side of the motivator opening. This meant a re-design, again, of the 'bell crank' component.

Am getting the hang of the clearances needed to make things a nice fit. I countersunk the hex hole for the lock nut into the component.

Well, the new position for the actuator fits, but is now at an angle that won't work.....

So looks like it's back to the drawing board (CAD) to look at another way to activate the motivator.

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Next idea was to just mount the actuator directly below the IGUS slide to push/pull the motivator unit. But where to fix it tho. Idea was to mount the bracket to on of the internal wood frame supports.
So I drew up this bracket.

The next thing once this is fitted is to design up the linkage from the actuator to the IGUS slide.

R5-D4 - Bad Motivator system upgrade 1.3

Ive had to do a few more re-designs on the motivator's activator bracket & pivot pieces. This is all new to me and although I sort of know the basics, a linear piston movement connected to a pivoting 'bell crank', didn't go the way I thought it would lol.

I decided to change the bracket for the pivoting bell crank, by making it a separate item. This means the actuator bracket can now be placed independently, maybe until I know where it should actual go lol

Downloaded the IGUS slide an assembled it onto the bracket. Along with nut, bolt and washer. Re-designed bell crank as well.

I found a supplier for the IGUS t-track and the price wasn't bad. I just now need to sort out the location bracket for the actuator.

R5-D4 - Bad Motivator system upgrade 1.2

One of the thngs that bugged me was trying to solder the wires up inside the e-cig unit. It was never 100% successful with weak joints, dry joints etc.

So I looked into somehow modifying a pre-assembled unit and figuring how to get the air to flow though the unit. I found this unit on eBay (last year, for about £6) as part of my testing atomizer units.

I had been using these types of atomizers....

.....and I may still come back to these,

as they are easier to refill in the upright position.

But for this testing I'm using one of these.

I enlarged one of the holes in the base to allow are flow into the atomizer.

Then in AutoCAD Inventor, I drew up a collar for the plastic tubing to attach too.

And here it all is assembled. I tested it by blowing through the tube myself. It works, though I still need to fine tune it a bit more. The air flow felt restricted compared to original idea (see above picture No.2) But this may be because of the battery packs restrictively small cross cut out slots.

The battery pack (black plastic part) is not intended to be used, it's just for testing purposes.

R5-D4 - Bad Motivator system upgrade 1.0

R5's pop up 'Motivator' system, was deactivated last year for an 'event'. Although the linkage used to lift the motivator is sound, the riser bars were starting to seize up a bit, so making the up and down movement not so smooth. The electronics side also needs a tune up as well, so this will be worked on too.

So after doing some researching, I think I found some new components to upgrade the set-up.

• I found a slide 'sample' unit in work from IGUS.
• I also ordered a cheap bearing loaded kitchen draw rail.

I'll be drawing up some ideas in AutoCAD 3D Inventor (in work) for how best to work these into the dome. But out of the two options listed above, I'm going with the IGUS drylin T miniature guide carriage.

I also looked and was toying with a new DJ Design's 'updated' Motivator resin kit. As he states on his website, he has updated the motivator to look more screen accurate, which it does. He does state that it's still only an interpretation of what it looks like, but it does look close to screen grabs I've seen.

Here's some of the pics of the 3D work.

This was idea Mk1

This needed some refining and was a bit over kill, even with the 'weight savin' cut-outs lol, so this now looks a bit like this.

Idea Mk2

Am already working on a possible Mk3 version, but it's more a 'what if' idea than a change to this design.

Lightening R5's dome

Started this the beginning of the month:

With the new lazy susan planned, I started also looking at the frame work inside R5's dome.

With hindsight, this would/could of been made a bit lighter, but it was all new to me and since building the R0-D4 dome, I've learned a lot. There maybe some weight loss possible, removing edges etc, but the main weight is the actual top of his head. 18mm thick plus a WHOLE lot of car body filler for the cone angle top where the pie panels are.

Well, the 'Bad Motivator' electrics board could be made lighter, so started with that.
Here's a before and after, after doesn't have the aluminium bracket in the pic as probably won't be using it.

weight reduction

I used a thinner piece of wood board. The extra material was later removed as wasn't needed. Which reduced weight a little bit more.

R5 really does have a 'Bad Motivator'....?

For the life of me I can't remember if I've actually tested R5's 'Bad Motivator' whilst his head has been connected to his body??? I've bench tested it wired direct to a 12 volt 12ah battery and everything works fine.

But the other night, whilst connecting everything up and testing, I noticed & heard that the actuator was making a hell of a racket and wasn't able to pop, like it did on test??

The smoke system is fine, but no 'pop'. Bench tested and all's ok!?!?!

The wiring hasn't changed and all's ok there.......so I'll need to look at this again. But don't have time at mo, with having to redo the 12 channel board and prep R5 ready for Saturday [loading Friday night].

For now, I've locked the Motivator in the up position & disconnected it's power. He will still have smoke and sound, so all good there :)

Motivator Pie hole - internal wall's upgrade

The internal walls of the motivator pie hole need some work done on them. So cut up some circuit board and shaped them a bit. Keeping it simple, the boards are flat with low flat chips on them. Then sprayed them up with grey primer. I added some holes and fed some thin wires through. These were glued in place with a few then being cut. I added these after the primer to retain the wire colours. I then sprayed some black over them. The can I used was old and rather than give a nice fine mist, it spat the paint out. Wasn't what I wanted, but actually, it's not that bad lol.

Next I painted the inside of the pie panels with grey paint, before glueing in the circuit boards. These had to be positioned so as to allow the motivator movement up and down. Once this had all dried, I got out some black pained and filled in between the circuit boards to darken the sides up and give it the burnt, smoke damaged look.

'Bad Motivator' - upgrade to power lift 'Blown' status 2.0 [You-Tube]

So I was happy that the pop-up motivator system working, but not really with them ended both at the same time. As, well, in the film, after the smoke stops pouring out of R5,

his motivator is still in the UP position.

So I ordered another timer relay (that was delivered super quick) and wired this up to the motivator's actuator. With the intention of having different switch off times.

So the smoke and sound ends (once sound is wired up) and then after a while the motivator operation ends and drops back down. Sound sample was added to video for effect.

'Bad Motivator' - upgrade to power lift 'Blown' status 1.9 [You-Tube]

.......sorted out the Motivator to lower back down after being activated......here's a VERY short video.

I fitted a simple rubber band to the actuator, so retract the motivator after the power switches off.

The noise from the pump vibrating on the inside of the wood dome, was a bit to loud for my liking, regardless of the fact that at an event you probably wouldn't hear it! So I uncliped the cable tie and cut up some foam, wrapped it round the pump and tied it back into place. This is now a lot quieter!

It may not look pretty, but it does the job lol.

I have another small addition for the electrics to make things look and act how I'd really like.......

'Bad Motivator' - upgrade to power lift 'Blown' status 1.8 [You-Tube]

Installation Time!

Got home last night and started on fixing the electronics board into position. But soon realised that this position was not a good idea! Do to the material being screwed to was flexing and moving the outer skin. So back to the drawing board.

Whilst looking inside the dome, it came to me to just make a bracket and secure the board to the inside roof, like everything else lol

So in work this morning, I got to cut up an angle strip of Aluminium and drilled location and fixing holes into it. This can now be fitted and all wired up!

So on Saturday, I fitted the bracket to the inside roof of dome. Then attached bad motivator board to the bracket. Had to do some power re-wiring inside R5 to sort 12 volt power to board, then using multimeter, adjusted the voltage regulator to 6 volts. Topped up the e-Cig unit with some more fog juice and here's the first test video in action.

There was a bit of wind when I video'd hence the gaps in the fog showing.

I'll adjust the timer once the sound is sorted. Next is to wire up the actuator to pop up the motivator.

'Bad Motivator' - upgrade to power lift 'Blown' status 1.7

Last night I trimmed board down the board so it can fit in this position. Will have to reposition the timer relay.

Dome wires previously set up for individual power of lights, motivator and smoke....not now required, so I could use these for other things (???) Only the 12 volt feed is needed to then be distributed to motivator and smoke via dome board.