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“The main part provided is the drive motor that power R2-D2’s right wheel, which comes complete with its own gearbox and circuit board. With this in place, you will be able to wire up and assemble most of R2-D2’s right leg.”
This may be our biggest issue yet. It has so many steps in it that they chose to skip the entire Understanding Robotics section of the magazine.
- Building The Galaxy – Industrial Light & Magic
- Droid Directory – B1-Series Battle Droids Part 1
- Build R2-D2: Model Instructions
Fitting the Motor and Wiring
Fit the square drive spindle of the Right Wheel Motor/Gearbox into the center of the wheel axle from Issue 28:
Align the motor casing with the four matching holes in the Outer Wheel Mounting Plate:
Secure the motor into place with four (4) 2.5×10 mm silver screws we received back in Issue 28:
Retrieve the Motor Cable from Issue 17. Connect the larger plug of the Motor Cable to the socket on the motor’s circuit board:
Thread the other end of the Motor Cable up between the leg and the Right Ankle Plate:
Feed the larger plug of the Infrared Cable from Issue 17 up the leg in the same way:
Slide a Cable Tie through this retaining loop on the metal leg frame, making sure it is orientated correctly for Step 11:
Before securing the cables in place, make sure the end of the smaller plug of the Infrared Cable is 5-5/16″ (135mm) from the retaining loop:
Loop the Cable Tie around the cables and pull it tight.
Make sure you leave a little slack in the Motor Cable here between the Cable Tie and the motor itself:
Repeat this Cable Tie process at the remaining three retaining loops in the metal leg frame:
Cut off the excess ends of all four Cable Ties.
Sprue cutters did a great job of this, but any sharp cutting tool can work such as diagonal cutters, nail clippers, etc.:
Fitting the Leg Casings
Plug the Right Sensor into the round hole at the shoulder. It should sit flush.
The front edges of this sensor are soft, so I recommend putting the front through the hole first, then sliding the back down into the slot:
Feed the Right Sensor lead out through the large hole in the center of the shoulder:
Feed the ends of both the Motor Cable and Infrared Cable from the previous section through the same hole:
Make sure the Right Ankle Mounting Plate is far enough down the leg, then align the inner and outer leg casings, paying attention to the protruding lugs and matching holes:
Slide the Right Ankle Mounting Plate up over both casings to lock them together:
Fit the Right Leg Outer Plate assembly completed back in Issue 2 onto the outer shoulder:
Secure the leg casings together with twelve (12) 2.3×6 mm black screws:
Turn the leg over. Then, take the Right Ankle Fitting assembly from Issue 8 and, noting the four protruding lugs and matching holes, press it neatly into place:
Turn the leg assembly over again, and drive one (1) 2.3×6 mm black screw into this hole to lock the fitting into place:
This Right Leg Bottom Rear Cover assembly has a recess (circled below) which provides clearance for the cables in the next step:
Fit this assembly over the inside of R2-D2’s ankle, making sure the leg cables are within the recess mentioned in the last step:
Secure the Right Leg Bottom Rear Cover assembly into place with four (4) 2.3×6 mm black screws.
The instructions are wrong here, they say to use silver screws, but they meant black:
The right leg is complete! We still have to add the foot coverings, but the leg itself is a beauty. There was so much to do in this issue. I wish all of them were like this, so here is to hoping for more ‘full’ issues like this one! The motor/gearbox is all metal in this issue.
Running Total of screws used so far: 161
Issue 31 – Outer/Inner Foot Casings