Alternative ‘colour’ booster covers 2022

Start date: January 2022

This has been another project I’ve been thinking of doing since the Mandalorian session two came out.

Droids are few and far between, but two have been quite prominent, R5-D4 & also NO-AH, first seen in the Jawa’s Sandcrawler. The colour scheme is very unique and I wanted to create this version myself. The dome itself was first seen/used on an A-LT droid for the Solo film. See promo pic below:

The domes are the same size as R2 dome so obviously are able to fit on an Astromech’s body.

A fellow droid builder has offered his large 3D printer to produce a dome when i require it.

Roll on into 2022 & I finally got round to making a start. First bit of research was the release of the Disney Droid Factory toy pack, and Wookieepedia, which gave us his name as ‘N0-AH’.

So I loaded up my 3D drawn boosters that I had previously printed and fit R5’s legs, and printed of the first one whole on my works printer overnight.

Next up was applying wood filler…..and free time.

Alternative 'RED' Boosters

Here’s the new ‘red’ Booster cover fitted on R5.

Just the ankle cylinder colours to change. These I think I'll just change by applying red vinyl.

And here's the link to the whole build/print process for them:

https://r5-d4astromechdroid.blogspot.com/2021/04/alternative-red-booster-colours-2021.html

Alternative 'RED' Booster colour's 2021

March

Something that I have thought about over the years, was being able to do a colour change for the Leg Booster covers. It has been talked about over the years, including 'covers'. I had thought about and tried, applying vinyl stickers, but this isn't a two minute job to apply and there's the very slight potential to damage chipped paint. I didn't fancy making another set out of wood again lol and had even thought about trying my hand at casting and moulding, something for the future.....

I decided on 3D printing them as these can then be swapped for R5's blue Booster covers. As my Boosters are 'unique' lol, although made to the plans, they're location pegs are custom, so I decided to draw up a set of booster's that would fit.

For the first cover, that I drew up in CAD, I split the file into three sections for easy fitting on my Tevo 3D printer. I then mirrored them in CAD for the other side, so only having to draw up once.

I added some some tabs to help with glueing the sections together, but this wasn’t acceptable for me.

So for added (guaranteed) strength, I hot welded the pieces together using a soldering iron.

(The boosters are hollow, saving print time and filament).

After some filing and sanding, I applied wood filler to joins and low spots. Here I've started applying, whilst waiting for the other half's to print.

I printed off four location pins, which will be fitted to each half section as can be seen in the picture below.

April

The second booster was printed in only four parts this time (rather than six), one piece ran out of filament just at the end, but not to worry as it still fits together okay.

Wood filler applied after welding the lower parts of the booster on. Still need to apply location pins before joining the two sides together.

Grey primer applied over the filler primer. Whilst this was drying I got on with sorting out the location pins for the second Booster cover.

Here's the second Booster cover, test fitted onto the leg. The location pins were again, welded onto the Booster cover, top and bottom. One of the lower pins needed a bit more modification to be able to locate and this was then also be welded to the cover.

Second coats of filler primer applied to the second Booster cover.

Next up was grey primer to the second Booster cover.

And whilst that was drying...... I was able to spray a coat of red onto the first Booster cover.

Really pleased with this!

Once fully dried, I painted on the silver detail first coat.

Next up will be a clear coat before weathering.

Leg Assembly......again

Last night I got to re-assembly Leg No1 again.

The way most of these components were designed to be connected together was not my 'new' idea. I have followed several other R2 Builders builds. And this, along with building the actual components, are mostly not original to me.

Adam Strawson's R2 was one of the first R2 Build's I followed.

The other being Emy by Podpadstudio's.

So here's all the parts....

Left pic shows the front, the right pic shows the rear fixing points etc.

For my build, I secure the Ankle Braclet to the Ankle 'curved' section with a small screw. This holds it in place and will locate the Booster Strut in place.

Next I secure the Booster Strut by inserting the bottom of it into the Ankle Bracelet, then a screw into a bracket on the rear of the top square part, picture below.

Booster Cover over the Strut, and press it down into the dowel location holes.

The other components, the Ankle Cylinder, cylinder wedge and support are already assembled as one piece. These are push fitted into the leg with dowels.

The last three items are the 'Ankle Details' these fit on the lower ankle sides, fron and back.
And the Shoulder Horseshoe assembly, which is pre-assembled.
The centre hub is also a snug push fit.

Horseshoe No2 - Hydraulic & Buttons fitted

To make space in the bedroom [keeping the wife happy] I took the Horseshoe back out to the garage and fitted [bolted] the Hydraulic & the two Buttons back on. Then fitted the spacer and finally, pushed the location pegs into the holes on the Leg.

Leg No2, is now complete :)

Battlestations!!! ;)

What with R5 being on display this Saturday, am a little nervous, to say the least!!

Been trying to get as much done and finished before the big day, so yesterday, I sprayed up Leg No.2 white. I gave it a few coats, but as the can was running out, decided to concentrate on the outside/front. I won't clear coat it till the whole leg has been sprayed, but it still looks good.

I also sprayed silver the second Hub, that didn't turn out great the first time. And the rear strip for the Ankle Bracelet.

Then last night I started to assemble all the components I had for it. I first screwed into place the main Ankle Bracelet. It's screw although countersunk, is also covered when the Booster Cover is in place. Next on was the Booster Strut, which sits in the hole of the Bracelet and an angle bracket secures the top block to the leg. The Booster Cover then is just a push fit with the dowels, into the leg. The Ankle Cylinder [with wedge & holder pre-attached] are push fitted into place, along with the two Ankle Details. The Hub is also just pushed into place for now. And lastly the Horseshoe goes on.

Lastly, I started to dirty up the whole leg.


**UPDATE**
I've now fitted the Large Data Port, touched up the Octagon Ports edges with metallic blue, fitted the lower vent pocket mesh screen.

Outer Foot No.2 - UPDATE
Been working on the crescent detail, to finish off the top section of the shell. Also drilled out the knurled hose fitting holes and added the top strip detail. Only going to be able to primer it up for the show tomorrow.

I give you........R5-D4

So, this morning, the kids were out doing 'activities' and the wife was out too, and to top it all the SUN was out shining and the wind was still.

Didn't take two seconds to realise, now was my chance to 'do' some work on R5.

So I assembled R5, legs, feet, 'aluminium' strip to feet channels, battery box on to check for clearance etc.

Whilst assembling, a gentlman walking his dog, by himself, said [to himself or his dog], 'Look, it's R2-D2!' So I was chuffed it was recognisable, then a bit miffed he got it wrong! hahaha :D.

Test fitting of outer foot internal to leg

Then on with the rest of the legs and feet.

 

And the pictures you and I have been waiting for............

R5-D4 standing on his own three feet.

This shot show's Foot No.2 is still a W.I.P.
I didn't fit the booster cover etc or the horseshoe.

This shot shows R5-D4's rear, rear hatch, opening into his outer foot

And back round to the side.

Close up of the Battery box fitted.

 

 

 

I also fitted the fake aluminium strips to the channels of the feet. They are screwed in place and these will need a spot of paint on them.

And here is the 'trimming' I had to do so the legs would fit into the channel of the internal foot channel.

This leg still needed trimming, but this time along the thick part of it. As it was touching the shell. Found this out when the leg and foot were assembled and the wheels weren't sitting flat on the floor.

Booster Cover No2 - complete

I've also been using the silver paint [pot] & brush to do the grooves on the booster cover. I wasn't to happy at first as it wasn't going on to thick, was used to the model paint I'd used before which did it in one coat. But after a few coats, it's not looking to bad.

next:
mark position on back face of booster cover for drilling and fitting of dowels.

Lots of work done......

Ankle Braclet
I cut out a piece of hardboard to fit at the back of the Ankle Braclet. Once sanded I sealed it with watered down PVA glue. It will need re-sanding once dried.

Coin Slot
Before I fitted the Coin Slots back into the body, I painted the visible frame black, that could be seen through the slots.

Leg No2
Sprayed primer over Leg No.2. This helps to show up all the bits that need attention! I wil also need to drill and add a few more stratigic holes to help clamp the pieces tighter together. I did this before then applying more wood filler to gaps and all over where needed.

Horseshoe
Whilst the wood filler was setting on the leg, I started spraying Primer onto horseshoe.

Booster Cover
Masked off the 'blue' on the booster cover and then applied primer over the lower half & in the grooves. Left to dry, then later I sprayed it up blue. Need to buy another small can for finishing off the Octagon Port wall edges.

Shoulder Hub
This resin item had already been cleaned, just not got round to painting it. So on went a few light coats of primer. A few as you want to get the paint in all the corners, without the spray 'running'. Spray, leave, spray a bit more, leave......you get the picture :)

Outer Foot Sheel No1.
I already had this piece cut out. I just needed to cut the angles & it to length. It fits on the back face of the foot [actually the inside part of the foot, where the 'foot battery' sits. I bonded it in place with p40. Ooops, when I taped it up, the piece was slightly too long when I measured to check squareness etc. Luckily I had some scrap wood that was enough to move the piece to make it the right length. And then left it all to set. Next I then cut plastic pipe I had for the curved section. Using my coping saw I cut away most of the board I had left on. I then used my dremel with sanding drum attached, to create the curve.

Booster Cover 2.5 - The second Leg

Whilst waiting for the glue to set, I set to work on paining the sockets in teh top of the Booster Cover. Unfortunatly, the small modelers tin of paint had become un-usuable. So I had to mask it all off and spray up with silver paint.

I'll have to buy some more, as I'll need it to do the grooves all over R5's body!

Booster Cover 2.4 - The second Leg

It's been over a month since I first wrote this post.

Wasn't happy with the fit of the Booster Leg Strut's top square piece sitting inside the dog house of the Booster Cover. It didn't go far enough up inside it. So got to work with a file and now it fits much better. I used up what was left of the primer and also the blue spray. No point in spraying all over as still have the grooves to cut.

UPDATE:

I also had to machine down the diameter of the Booster Strut, as it was a bit snug fitting. The Cover opening was at fault.

UPDATE 04.01.13

I marked up and using my dremel, cut out the grooves in the Booster Cover, next is to primer, blue spray and clear coat.

 

Booster Cover 2.3 - The second Leg

As I said the other day, been working when I can on R5's body and also his second Booster Cover. Here are some photos so far.

Here you can see the cardboard 'frame' I made up and the first application of wood filler.

And here's the end result, and after sanding with a tube to get the curve.

As I was spraying some other parts, I sprayed up the Cover, to help show up area's I might of missed with the wood filler.

Filler in the gaps.

 

A small update......

Not been able to do much work on R5 these last few weeks, which is a little frustrating. Family holiday, decorating the home, health issues to deal with. But I have managed to do a little bit here and there.

Booster Cover

I made up two cardboard boxes, wrapped with selotape, and applied wood filler around them to make the two recessed areas of the curved section. Have to sand the curve in and see how it holds up. Attempt two will be P40 resin, as on cover no1.

R5's Body

I sprayed the lower area of the body with white paint, mainly around the front Octagon Port. This is so that I can touch up the Port itself with blue paint. I still have other areas to primer spray still, but this way I'm still able to do little bits. Once all the primer has been applied, I'll mask off areas and give R5 some more coats of white. Am not to fussed with him not being perfect, all this will (I hope) just add to the weathered & used look.

Octagon Port (rear, No2)

I've cut to size the angle bracket needed to secure the rear octagon port in place. These aren't really needed, but they do help secure the centre aluminium piece of the port and will aid the port from potentially being 'pushed' through into the body. The area inside the body will of course be bonded to the octagon port with P40 resin as well.

Battery Power

Lastly, I've put on charge a 12v 17amp battery, I found I still had lol. It was out of a not so good car jump starter pack! It may/will come in handy, and if nothing else, it is giving me an idea as to the kind of weight R5 will have inside him.

Booster Cover 2.2 - the second leg.....

Sanded the wood filler, all over the Booster Cover. And then using my Coping saw, I cut out the centre part of the 'Dog House'. I then bonded it onto the Booster Cover using P40 resin. Once this is dried, I'll file/sand it all smooth and then apply wood filler and then repeat.

Marked and cut out the four vertical grooves at the bottom. Drilled and screwed, from behind, the top section. I then marked the curves and using a coping saw, cut the curve out. I then covered the lot in wood filler & have started sanding......all over. lol.

Booster Cover 2.1 - the second leg.....

Cut the other angle, then marked & cut out the centre section.

Filed surfaces, applied wood filler where needed. A knot in the wood needs seeing to!

Then started on marking & cutting to size the 'Dog House' piece.

Booster Cover with centre section cut out.

Booster Cover with Booster Strut & 'Dog House' piece

Close up of 'Dog House' section