R4-D4 dome lid modification - part 5

 Right, on with the next re-re-design.

This first test print was in two parts, but could be combined into one. I did it as two for best print orientation purposes. Managed to get a good print and the piece fitted together perfectly!

The hinge part got strengthened up to stop any flex. The pivot pin holes were also reduced in diameter. All adding to less play between the components. Meaning, hopefully, less issues with alignment of the lid when closing.

Testing clearance of servo arm in closed lid position.

This will all be controlled with the Life-form scanners activation. But to add some flexibility in the lid servo movement, I’ve test fitted some springs.

Next up was to glue the panel onto the lid panel & the magnets onto the underside of the main lid.

Mixed up some more Araldite to attach the 3D printed part to the wood lid. This was clamped in place. One of the clamps slipped a bit so the 3D part moved out of alignment for where I wanted it :(

Once dried I mixed up a small amount for the first magnet. I placed a piece of masking tape between the magnet and washer so the Araldite wouldn’t bond to parts not required to be bonded.

I then clamped in place.

I bonded one magnet at a time to help with alignment of the panel. Once first magnet had dried, I went on to bond the second magnet in place.

.....next is to paint the parts again.

R4-D4 dome lid modification - part 4

 Found some steel washers the right size to fit in the recesses of the servo holder hinge side. These I fixed in place with some Araldite glue. I chose to place these inside rather than on the lid itself, so that the magnets once glued to the underside of the lid would locate the hinge in the correct position.

This is the redesigned holder, which also has a recess to allow a small threaded retainer to be located to have the pivot hinge pin secured in place.

Here’s a test layout picture before it was glued in place.

Next, was gluing the first washer in place on the actual lid panel. I applied a strip of masking tape between the magnet already installed in the hinge and the washer which was being held by it. I then mixed up the glue and applied it to the face of the washer, before clamping it into position.

After testing I found that there was a bit too much play with the locating part of the lid panel magnet. So had to go back and have a re-design......again lol.

This new design does away with this magnet/washer and will hopefully just be fitted directly to the lid panel.

R4-D4 dome lid modification - part 3

 After two design attempts, third time was lucky lol.

And got itself 3D printed off.

I added a recess and opening for a single LED, in the design. After I had re-levelled the printer bed before printing this third version.

After cleaning up the print, it got a coat of filler primer paint. Whilst this was drying, I got on with other parts of this project. The lid panel opening edges had a coat of silver paint.

The lid panel’s underside had a line added that would need wood filler to smooth flat. After it had dried it got a light sanding. It and the lids edges then got painted silver. (See above picture).

I decided to spray the 3D print, mat black and then dry brush it with silver paint.

I mixed up two part Araldite to fix the 3D print to the underside of the panel lid. Remembering to fit the LED lol. Whilst this was setting, I mixed up some more to fix the magnet into the servo arm that will fix onto the lid panel.

The servo holder has also had some re-working done, to incorporate two magnets that will secure it to the inside of the lid.

.....picture to come.

R4-D4 dome lid modification - part 2

 Did some 3D design work for a servo pie panel hinge.

Yes, there are ones out there, but they are designed for R2’s dome (curved). So after looking at some, I designed version 1, that hopefully will work. It also has to be able to be mounted to the underside of the dome lid, which isn’t very thick. So after testing this version 1 out, version 2 may have to be slightly different to be able to be mounted.

So version 2, incorporates a larger area to allow a magnet to be glued into it. This would attach to the lid panel with location pieces of wood perhaps and them glued in place?? The washer would also be glued to the lid. The servo holder part may also need to be updated to be able to be secured in a similar way.

Had another idea ......which I liked better than securing the magnetic hinge part with wood. I drew up and printed off a 3D panel which looks ‘mechanical/electrical’.

More in next post....