R0-D4 dome upgrade 2017 - 1.7 - 3D printed Dome Rods **UPGRADE**

Test fitted the first new dome rod the other day. Due to the internal angles of the wood when it was glued together, these are not perpendicular, so I had to file the ends slightly for it to fit. I know I'll have to do the same with the others.

Next was to drill location holes to hold the new rods in place from behind. The previous rods were slotted into a bottom hole and secured with a screw at the top.
Then its sanding etc before spraying up.

R0-D4 dome upgrade 2017 - 1.6 - 3D printed Dome Rods **UPGRADE**

So this was my first attempt (white piece),

alongside my original incorrect silver painted ones.

Needed refining and re-sizing as didn't take depth of my recess panels into account.

These are a work in progress still......

R0-D4 dome upgrade 2017 - 1.5 - 3D printed Dome Rods **UPGRADE**

Since Celebration Europe 2016, I've been meaning to get back to

sorting out my R0-D4's dome rods.

I snapped a pic of Lee's R0 dome he brought along.

And instantly realised how wrong my dome rods were lol.

These are definitely a LOT better than the ones I drew up and had printed lol.

So I measured up my dome slots and got to drawing up on

Auto CAD Inventor (in work) and scaled up a version to fit.

I gauged by eye, so mine will only 'look' the same,

but not actually be 'correct'.

First attempt.

Next up is 3D printing a set up, WIP.....

'R0 dome build - 4.5- 3D printed dome rods, fitting'

Free time at the weekend:
I filed the diameters on the rode's to smooth out the printing. Next was some light sanding with paper. Its more heat/friction from the file, than actual 'cutting' that makes the surface smooth I've found out.

Once cleaned off burrs etc, i got out my mini spray booth (its a big cardboard box) lol, and sprayed the three up with grey primer. I had already marked each one so i knew where they would fit back into their recessed boxes.

R0-D4's fitted Dome Rod (1 of 3)

R0-D4's fitted Dome Rod (1 of 3)

These are NOT 100% accurate, but will do for now. Next thing is to complete the new LED panel and then add some weathering to match up with R5's body.

'R0 dome build - 4.4 - '3D printed Dome Rods'

So my Boss was kind enough to print off three dome rods, a few days before Celebration Europe. But I didn't have the time to fit them. This will be next on list of things to do.

Whilst at CE3 tho, Lee brought along his R0-4L0 driod to display along with all the others.
The actual design is different to the version created. I may upgrade to the 'actual' design later on, but for now I'll work on these.

My #SWCE report is coming soon.....

'R0' dome build - 1.9 'recessed boxes'

Using Lars' plans as a guide to help with my wood build. I marked and cut out the inner pieces to make up the recessed box.

Drilled one large hole for the dome rod to fit into and a smaller one for a screw to secure in place. This one goes at the top for easy access. Lol, learned my lesson when doing R5 :-D.
The lower larger one will be fitted with a piece of wood to stop it dropping through.

Applied PVA wood glue and clamped box in place.

Once dried I added wood filler to the gaps

And some glue to the rear joints to soak into the gaps.

The plan is to cover these and joins with fiber glass matt for strength and security.

'R0' dome build - 1.8 'Skin - recessed boxes'

27th April

I checked the off-set needed so that the recessed boxes, wouldn't interfere with the internal verticals. Once happy, I marked the first box.

Cut out the first hole for the recessed boxes (3 off).

Then I measured and marked up the strips that will be the skin recess/step. I roughed up the smooth surface a bit with sandpaper first before I applied wood glue and whilst letting it to set a bit, I grabbed some scrap wood and my G-clamps and glued them in place, one at a time.

Next (pic below) on with the second side.

For the upper and lower pieces, I cut vertical slots in the back face, to help them bend a bit to the dome curve.

Then roughed them up with sandpaper before glue and clamping into place.

These have held really well (I sound surprised, lol) The opening is a lot stronger and once the rear recessed boxes are in, will be super strong.