Flag Banners: DIY Build (not yet completed)

April 2024:

I had an idea to utilise a load of PVC tubing i had in the garage. By turning them into flag banners. I went with the pivoted top that would move in the winds direction, hopefully preventing it from being blown over.

So I drew up and 3D printed the top piece first to check for size.

When I got home, I tested it out, i then drilled through the banner arm, and secured it to the pivot top with pop rivets.

As an example I knocked up this to see what it would look like.

Thinking I might need a bottom arm to hold the banner down.

I did drew up some rings and 3D printed them for the flag pole for the banner to be attached to, but I think the arm is a better option.

Spoke with the group about printing double sided & looked online, not very cheap though. Then I found a shop on Amazon, considerably cheaper!

Messaged Mike if he could modify a higher resolution image, he said leave it with him…..

I found that the PVC tube was a bit too flexible, but I found some smaller diameter tube which fitted perfectly inside, which helped with rigidity.

I drew up an angled bracket to help support the top arm.

October 2024: not yet completed.

Treadwell WED-15-77: mast box build (not yet made)

March/April 2024

With the tracks completed (at the time of writing this), and after making the head box, I needed a storage/transport box for the ‘mast’ section.

This was going to be built using the same design as the head box. I 3D printed the corner pieces again and then modified a copied version into a middle section.

I bought some more carbon fibre wrap and plastic edging.

October 2024: this still hasn't been built yet.

FunkoPOP Treadwell Droid WED-15 (Version 3C)

So here he is, version 3B, version 3C

As I mentioned in the last post, version 3, had been modified so that the claw end was supported once printed. I also added some other small details, because I wanted to lol , the pincer utility arm was added and more de-find (hence the B now C designation).

So this was version 2 below :

Version 2: main claw arm supported by mast at bottom.

Comparing original Version 1 (left) with Version 2 (right)

Here is the 3D render of version 3C. Picture below.

Didn't get round to painting him, but this is how he would look.

I've uploaded this version to my Prusa page, so check it out.

Treadwell WED-15 : Head Box build - part 2

January:

Note: Handles arrived, 😂 lol but the weight of the box isn’t enough to overcome the springs in them 🙄😂. So I went back to my original idea of 3D printing recessed handles.

Checkout part 1 of this project.

The first test one was okay but my middle finger knuckle would make contact with the edge opening. So revised this for version two.

Printed version 2.

Marked position and drilled/cut out opening.

Was a nice snug fit.

Just needs a dust off and pop new plastic pop rivets in. The metal ones were to much and started to damage the plastic handles. These plastic ones, just help hold the handles in place.

On to handle no2.

Time to cut the foam.

First piece being test fitted.

Next pieces.

The sides will need cut outs for the handles.

Picked up some spray glue to stick the foam in with once all pieces are cut.

Treadwell WED-15 droid build : Part 23 - woodwork, 3D printing, test drive

 

January into February 2024

Have been working on:

• Power
• Wheels - drive axles
• Axle bushes
• Polypropylene washers
• Electrical/electronics
• Bodywork
• History…….wait what???
• Details
• Testing, Testing, 1, 2, 3…..

After the last post, I knew I needed a proper to-do-list. Most of it is not directly related, more reminders lol.

Power:

Going to go with a single 12v battery for now, borrowed from R5 for now.

Wheels & Drive Axles:

machine up some proper axles for the two drive wheels. This will connect to the motor via a coupler that I machined up myself.

Next up was to machine up 1 of 2 drive axle couplings.

Coupler being machined for M5 grub screw

The actual wheel bushes and location end pieces for the axles fitting into the wheel, needed to be slightly modified and re 3Dprinted.

Axle Bushes:

Machined up the rest of the Brass bushes that are press fitted into the wood side panels. I reoriented them so that the lipped edges are inside the frame.

The two main drive wheel bushes are slightly longer to take up the space between the side panels and the couplers. Bottom left rear wheel doesn’t have a coupler or motor fitted at time of picture being taken.

Test fitting of the wheels, temp tracks and motor no1,
to see if it has enough torque to drive

Polypropylene washers:

3D printed off a load for both outside and inside.

The axles are then locked in place with M8 Nylon locking nuts.

Electrical/Electronics:

• Ordered a Sabertooth speed controller from the Robotshop. PayPal allows you to pay in three monthly instalments, very handy.
• Ordered some 12 gauge red & black cable.
• Ordered a 12v geared motor & on testing, ordered a second one.

Sabertooth speed controller

Bodywork:

Tapped up and filled in the front and rear gaps for the cut angled faces. I used glass fibre filler, P40. 

P40 glass fibre body filler

Then applied P38 body filler over the face.

Sanded smooth, ready for more paint.

P38 filler applied, Pre-sanding

Next up was the side axle cover plates.

These I drew up in CAD. The inner bracket is my own design. It is also the wheel axle guide. Got some M5 flanged head bolts coming, to secure both axle plates.

(Temporary bolts fitted in pre picture)

History:

Have been trying to find the original electronics used, speed controllers (x2 off). These wouldn’t of been your modern electronics speed controllers (ESC’s), but Transistorised versions!

Still trying to track the actual ones used etc.

Details:

I noticed that the antenna has a black (possibly rubber) end piece, before the aerial rod. So I quickly masked it off and sprayed it black.

Testing, Testing, 1, 2, 3…..

I wanted to know if the new motor had what it needed to drive the tracks. So I fitted the wheels as best I could, some didn’t have some of the bushes or proper securing nuts. Added the ‘display’ tracks I made last year for display purposes. Hooked up the battery and connected the motor.

Video link.

Not the best and didn’t have full control , but it was just to test it worked.

Next up:

• is fitting the new motor and brackets, when they come.
• Installing the electrical components.
• Machine up another coupler.
• Machine up two final axles.
• Test fitting everything inc mast and head.

Finally, I need to make the new tracks, but need to purchase the materials first.

Treadwell WED-15 : Head Box build - part 1

December 2023:

Head box - transportation/storage

This was something I needed, so I measured & sketched up a suitable size box, allowing for foam padding. The box lid is going to be the top third of it, so that the foam insert, helps hold the head in place.

• I already had 3mm thick wood hardboard.
• Bought a length of some black 90° angle plastic.
• Bought some carbon fibre wrap and some catches.

Cut some of the wood to size, but didn’t have time to cut the fourth panel. (Forward to January 2024). All the panels are going to be secured with pop rivets……hopefully. They seem to be doing okay so far.

January 2024:

Cut the fourth panel out. Then cut all the panels to create the upper lid pieces. The smaller pieces in the picture below. [These I didn't actually use].

Cut to length the 90° angle plastic, and miter trimmed the edges.

Cleaned the edges and then took them inside the house to measure up the available wrap.

I made sure there was enough to overlap the edges and stick to the inside faces. I also made sure that the wrap weave was all going in the same direction.

Next was to mark and drill holes for the pop rivets. Not sure yet if i need to add a second internal 90° length of plastic.

I marked and drilled each hole one at a time and used rivets to help locate correct position for the next hole.

Corner pieces: Base

Looked at buying some, but wasn’t happy paying for something that wasn’t going to work with my design……so I drew one up in CAD. Added recessed so that the plastic angle would fit underneath. Securing holes for fixing to the wood panels. Added some ridges to the sides.

First 3D print worked. So set the printer to run overnight. These didn’t print, need to check and clean the printer??

But got them printed in the day. Am really happy with how they turned out. They really add rigidity to the box sides.

Next up was to add plastic side edges, drilled and temp held in place with rivets.

Corner pieces: lid 1 & 2

I then got on with designing and printing the lid corners. These have a lip to fit over the sides and then a recessed lip which will hopefully align with the upper lids corner pieces.

The upper wood pieces previously cut, now aren’t needed as the box has enough height to accommodate the ‘head’ + foam insert protection. [measure twice, cut once lol]

The upper lid corner(s) was drawn up for 3D printing. These have one length edges as well.

Next up was the edges around the lip of the box. These incorporated flats for the clasps. First lid corner/length piece printed, sketch image above, and picture below.

Even after cleaning the nozzle, the Ultimaker is still acting up, so can’t do any overnight printing. Came in next morning to find print had paused again.... noticed an exclamation warning...... on clicking on it, it showed the print HAD paused at layer 69, because I had told it too!!! 😂😂😂😂 I remember now seeing if the pause function worked, but as recent prints weren't high enough, I had forgotten this tick box. Hopefully everything will be back to normal.

First box length piece printed, after pause restart lol. I printed it longer than needed so it could be trimmed down to size. It's not a tight fit between the corners.

I drilled a hole for the pop rivet. But will add two more either end [see image below].

Next up was to position the clasp and screw it in place.

Each day, another piece was printed. To help strengthen the lid joins, I've printed some corner that fits on the inside edges.

The box isn’t going to have a lid handle, but two side ones. These I've bought off eBay.

I also printed off some yellow infills to identify the front orientation fo the lid to the box.

I’ve ordered foam for inside, so fitting of this and the handles will be in part 2.

R5-D4 Funko Pop inspired 3D model

Each week I usually focus on just one particular project.

Recently though, I’ve been working on a few.

• LED’s light strip, see workbench upgrade post, coming soon……
• A ‘vintage car’ glovebox 3D printable, stronger version than the original cardboard one
• And something that I’ve wanted to do since the ‘original’ 3 legged R2-D2 concept Funko Pop came out….. Model R5 as a 3 legged version.

Funko beat me to it with their twin set of R5 & R2 at Celebration Europe earlier this year 2023.

My Pop is stored away, so this version is a modified version of my own R5 that I modelled years ago, for all the R5’s variants Funko haven’t produced, with its own unique angled stance and new 3rd centre leg, with single ankle cylinder, just as the 1977 R5 should be. This is now available for download in my Etsy shop.

The body to leg (shoulder) mounting location was modified to a suitable angle. The leg ends also had to be modified to accept the outer feet. Finally, the centre legs ankle and cylinder had to be modified.

Specifically for individual part printing.

But my first test print was a fully assembled model version, see above Cura printing image.

First test printed really well, though I have made some adjustments to the rear panel gaps, corrected a few other little things.

Next idea was to produce a detail drawing showing the views of the 3D model. I was thinking about uploading these to my Etsy page as an additional downloadable purchase…..

May even do a special offer for the first 5 downloads of the 3D file(s) that the print is  included 👍🏽.

I still haven’t done an R2 style dome yet, but it’s  on my to do list.

I do have the R4 dome as well as the R5 special style dome of R5-PHT from Solo a Star Wars story.

So I’ll make versions of these too......

👉👉👉👉Link to my Etsy Shop

Treadwell WED-15 droid build : Part 21 : Base / arm 4 upgrades / manual

 This post covers a few topics:

• Base problem 
• Arm 4 alternative version
• Arm 5 claw 3D printing
• Arm 5 claw articulated 3D version
• ‘Stick Droid’ manual - John Stears
• Propstore auction - R2-D2

September:

I noticed a few months back that I’d missed a detail, whilst following the plans. They show the front lower edges as being 90°s but are actually angled like the upper edges.

See picture:

So I’m going to have to modify this somehow!

This will require the removal of the front and rear screws from the bottom (done).

Next, I marked up the cut line.

I just need to get hold of a circular saw…..

October:

I dug out my Star Wars encyclopaedia just to see if it had any treadwell stuff in and it did!!!

This is quite a clear image. One part that caught my attention though was the lower left utility arm.

Previous images give the illusion that it has a cylindrical ‘mesh’ around part of it, but in this picture it looks like half cylindrical discs, similar to old electrical contacts.

Zoomed in picture:

You can see from the contrast highlighted centre area that there’s a distinct stepped layout of the layers. I went with cylindrical discs as this still matches up with the other images.

So i drew this up in AutoCAD and 3D printed the new pieces. I CAD’ed them up in half sections for the arm and the discs as separate parts, this results in better quality prints, less support waste, but also better painting opportunity.

To help with alignment, I added a location ridge and groove. The image above shows this, the ‘discs’ are a close fit but the CAD image doesn’t account for the filament expansion, hence the gap.

Next up was another arm the same as the claw one, but this one will be static.

I ordered another claw from Amazon & have painted up the 3D prints.

October 20th:

Continuing on with the slow progress, I found time to measure (using a digital vernier) and draw up the ‘claw’ end pieces. I made the claws a little thicker to add strength, then 3D printed off a set. I also printed off an internal piece to help locate the claws when I glued them in to place.

As part of the development process and creation, I drilled holes and added pins to recreate the pivot points (as shown in previous image no2).

This version is a fixed claw one.

Started at attempting to do an articulate version.

There is definitely movement lol

All these models will be going up on my Prusa account, once finished.

Propstore auction: November 2023

Two items got my attention (neither I can afford though 😆) and these were the instruction manuals crafted by John Stears, for the droids in A New Hope, in particular the ‘Stick’ droid or as we know him, WED-15 Treadwell droid.

I have always wanted to recreate this manual in full. Utilising copies already found over on the www.rebeldroids.net forum as a guide, I was able to search and found some high quality images of the manual, via a previous auction (site) from earlier in the year.

So I saved these and added them, along with some pages I had to recreate.

I will include an updated section, specifically for my own build.

The second item is the R2-D2.

This is because I know the owner personally, funnily enough, all the recent droids that have come up for auction via the Propstore, I’ve known the owner's. Fingers crossed for some good bidding 😎👍🏽