Full Size R2D2 on a budget

This is a prop I built for a Star Wars party. I didn't want to spend a lot, but I did want it to look cool.
I know that there are some incredibly talented folks who put years of effort into making awesome R2D2 and other droids, but I wanted something inexpensive and I only had a few months until the party. So rather than use sheet metal and fiberglass, I used mostly cardboard and wallboard joint compound. I also use a lot of stuff  that I had in my junk-box.

Yep - that was once a used refrigerator box!

Step 1 R2D2 frame and covering

I found some pictures on the web and once I found the overall dimensions of R2D2, I was able to calculate the size of each piece. R2D2 is about 43 inches tall and the body is about 18 inches in diameter (not counting the legs)
Google image search is great!
I acquired a few refrigerator boxes at a local retailer and got to work.
I created a frame for the body, then wrapped the cardboard around the frame.
This is a bit tricky. You'll need to soften - but not drench - the cardboard by spraying it with water and letting the moisture soak through the layers. When it's sufficiently soft, you're ready to wrap it around the frame. Apply hot glue to the edges of the frame and attach the softened cardboard sheet to it. I recommend that you get some assistance with this step.
It has a few inconsistencies, but we'll compensate for that later.

Comments

[Conas]

Very nice man!

This IS the droid we've been looking for.

[Wintershot]

*groan*

[Dusk Shadows]

wow you can't get better than this

[Wintershot]

Well you can but you'd have to break into George Lucas' house.

[Dusk Shadows]

nice

[vroom...vroom...]

I think his legs are shot long. But other than that,it's amazing!

[ljm12#]

dude this is awesome im so trying

[zomfibame]

Nicely done R2D2.

[fenris]

I guess I am a famous quibbler in some circles - well, I study languages, and I always try to push people in the direction of correct use of words and phrases. So - if "droid" is short for "android (robot)", meaning a humanlike robot, then C3PO is a droid and R2D2 is a robot. It is correct to say both are robots, but it is NOT correct to say both are "droids" - yeah, I know, they did that in the movies, but that doesn't make it correct. If 50 million Frenchmen all agree that the moon is made of green cheese, that does not make it so. For droid to enter the language as a synonym for robot is very unfortunate, and frankly, stupid, IMHO. Better if we all cooperate in trying to improve our language, rather than degrade it farther than has already been done.
Thank you for you attention, and sorry if I am being a drag.

[cmccormick1]

so fenris you wouldnt believe 50million french people but would you believe the person that created the moon....the same goes for a secret recipe, you wouldnt trust just anybody on the contents except the person that wrote it. So doesn't that make it reasonable to trust George Lucas when he claimed r2d2 and c3po both as droids but separate varieties? r2d2 is not the same as c3po correct, but that is because he is an astromech droid and not a protocol droid such as c3po.

[nbrett]

R2-D2 is actually a model of Astro-mech

[michellev73]

Dude - since "droid" in this case is being used in reference to someone's intellectual property, using another "more correct, IYHO" word would be wrong. The moon is green cheese analogy is stupid. If George Lucas says R2D2 is a droid, then we all must refer to him as a droid, to do otherwise would be demeaning his creative works.

[davidfarrell116]

you have way too much time on your hands !!!

does putting people down make you feel better ?

maybe you didn’t realise you were putting that person down but you most certainly were

[Crap its Yumi]

There's more than one way to be "humanlike". Just because something isn't in a humanoid form, doesn't mean that they can't be humanlike--and in this case, R2D2 clearly displayed emotions and reactions attributed to humans. So it isn't incorrect to refer to him (it, whatever) as a "droid" or android. Perhaps you should look at the subject matter more thoroughly and consider all the possible meanings of the words instead of just a single narrow-minded one, because in this situation you were being quite rude in addition to being wrong. Since you say you study languages, then you should know that common language is constantly changing and growing to accommodate new needs. Language isn't something that is set in stone, and a new developments and associations in meaning isn't wrong or a "degradation", just because one person trying to act highbrow says it is.

[smithinca]

Seriously?

[eklein1]

I want to make a smaller sized one of these, and I think maybe an extra salad bowl with a flat bottom, plus a styrofoam dome to even it out. That way you don't have to buy and carve a huge chunk of 'foam and you have a nice rounded top.
Then coat the whole thing with paper mache or the wall joint stuff and paint.

[gonzalorojoaguirre]

Great job! awesome.
try; http://astromech.net/

[Knuxz]

Don't mean to be a downer, but you forgot the third leg. You know, the one on the bottom of the actually unit.

[michellev73]

the third leg is only used when R2 is moving, not when he is standing. You can see this clearly in Ep. 1 when they go out to fix the ship that was damaged when leaving Naboo.

[Knuxz]

That is very true, so I guess this doesn't move. Haven't read this Instructable in a while. Since. "Nov 7, 2010. 12:34 PM"

[redcomet002]

actually, the third leg is usually retracted when R2 is standing

[mustachedude64]

no it doesn't the only time it is out is when he is standing, dude have u not seen the movies?

[redcomet002]

Really? Check again

[mustachedude64]

have u seen the runaway r2-d2 video in the special features it is a funny "fake" documentary about r2-d2, since u have this much passion for star wars u should watch it

[mustachedude64]

dude but what about every r2- unit action figure they ever made wouldn't they have a retractable third wheel too

[redcomet002]

it's been a long time since i've had an R2 figure, but they've all had a retractable third leg.

The 3rd leg astromechs have needs to retract in order to fit inside the slot in the back of a starfighter.

[Knuxz]

Well then make it move. XD

[matt.e.jenkins]

What a great project. He looks great! Good job!

[tinker234]

(removed by author or community request)

[jamerperson]

Why would you waste something as beautifully made as this and make a trash can out of it!?

[chillman1]

anyone have a copy of the pdf download that they'd be willing to share? This looks like a great and fun build project.

[Dandolion]

Silver Spay Paint sometimes can be sealed with clear to make it more durable. Try buying a clear sealer from the same paint manufacturer and painting a test piece and sealing it.

[tinker234]

could i kmake a robot with this

[tinker234]

could i do it in sheet metal and wire

[wamj]

hey, beautifully done project, this is probably gonna be the first step in my next project which will be a (almost) fully functioning artoo unit that speaks and moves and follows people and what ever else i can think of

[onemoroni1]

Very cool. I don't get the critical comments, it's like man, if your not not making something here, bug out and bother the people on Yahoo news comments. you'll find lots of shallow minded critics there. If the word droid is an issue, take it up with G. Lukas, he's the one that perpetuated it in his wonderful world of Star Wars fantasy.

[Centaur1]

Have you thought of Strofoam? Just the desire size styrofoam or connect two styrofoam with glue. Cut it into a rough shape, then shave a-little closer to the perfect dome.

After your done, you use paper mache to smooth out the surface and then you paint the design.

[libed91]

This is great, but where is R2D2's third leg?

[tallcan]

Damn Good stuff!

[SoapyHollow]

Dude, wow. That is dedication to a party theme. :)

A couple of people have mentioned bowls, which I don't think are going to be the right shape, but perhaps hemisphere baking pans would work? They come in a variety of sizes, and are perfectly round hemispheres. It's what bakers use to make planets, baseballs, etc.