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!

Here's a site that I found very useful: (especially the Autocad .DXF files)
http://files.astromechbuilder.com/attachments/?dir=/*2003_Archives/9-September_2003

also:

http://starwars.wikia.com/wiki/File:ArtooBlueprints-SWBTUC.jpg

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

[cwarren7]

Thank you! i am on the last step (mache the head) but i have one more question: do you by any chance remember where you found the logos?

[BrianH]

I found the dimensions on this page - with a lot of other helpful info too:

http://files.astromechbuilder.com/attachments/?dir=/*2003_Archives/9-September_2003

look for the .DXF (AutoCad files) that start with the prefix JAG200

[cwarren7]

how tall and wide are the legs? im building this right now and it works!

[BrianH]

Sorry for the late reply - The legs are 31 inches tall and (side view) 8.75 wide at the top and 4.5 in the middle. From the front view, they are 3inches thick.

[alexanderall]

You said that r2 is 43 incches tall, Is that from its feet to the tip the dome or is it the size of the body?

[BrianH]

43 inches tall from bottom of the feet to the top of the dome.

[Dzucky]

what did you use for the pillars of the frame in step one? was it wood? (just checking)

[BrianH]

The 'pillars' are wood one inch square if I remember correctly.

[cwarren7]

Awesome! doing it right now! thanks for sharing!

[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.

[antennas]

Yup major drag. If 50 million don't care..well you know the rest.....

[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?

[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.

[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.

[shtihl]

that is awesome. i think it came out great.

[jerhpk]

try a large stainless steel mixing bowl for a rounded shape. or a wok, available at many restaurant supply shops. They will not be perfectly round, but they will provide that shape at the bottom.

now back to reading this "fresco frijoles" 'ible.

[ComJSF_TSV]

Love the BUILD project and may I say you have done a gr8 job.

Later seeing that the head can be removed, you could do either or both of the following:

Use a PICA Laser Projector (Small enough to fit in your hand.

Add a small motor with a wiper blade motion, it would add that something extra.

Thanks for sharing your BUILD

JSF_QLD

[jholst]

Excellent 'ible. Definitely going to try this one. I can also see doing something similar to construct a "life-sized" replica of Bender from Futurama...

[BrianH]

I love Bender!! Let me know when you do yours.

[ReVoon]

What about using an inexpensive large plastic salad bowl? These will usually be at 99¢ stores and the like around the holidays. I would get one just over 18" dia and very deep for a nice round look. Just a thought. Beyond that, a very nice, well-executed design.

[BrianH]

Yep - that's another thing I looked for, but the bowls I saw had flat bottoms, and I didn't find one that was the size that I wanted. Also the shape is not quite right for my R2D2.

[profpat]

wonderful project!

[seltzer10]

Nice man i like it but if i was going to do this i would use a concrete casting tube, you can get them for like $10usd. but i like it,very nice ible.

[BrianH]

Funny that you should mention that... I considered that, but I couldn't find one in the exact right dimension. I found 8in 10in or 12in tubes, but not 18inch. It's all about the dimensions!

[switch62]

Just love it.  It's a great prop and I want one :)

With the head maybe a stainless steel bowl could be used.  But since the head is not just half a sphere it probably would'nt work without a lot of tweeking.  One thing that comes to mind would be to make the basic paper mache head as you did, just less paper and foam.  Then use a nail in the top centre with cardboard template attached.  You slap on the jointing compound and spin the template around slowly to form the final dome.  Think I saw an 'ible for making circular 3D objects this way.

Hint for silver spray paint, always put a coat of clear over it.  Otherwise the silver always rubs off.  If you use auto spray paint, it's more durable but doesn't look shinny unless you clear coat it

About R2D2's third leg -  In the original movie they had two R2D2s.  One was a remote controlled version with the third leg to stop it falling over when it moved. Notice how it's always leaning at a backward angle.  The other had only 2 legs and a small person in it to do the side to side walk and shaking scenes.  It's always upright.

[lynellephi]

Um, actually they had over 20 R2's in the original. The third leg was asthetic based on Ralph McQuarrie's designs (you can see a pic of the actual original drawing that was at CV on my blog). The back legs are what keeps it from falling. The center foot helps with the balance for steering only. The small man inside the 2-legged mode was Kenny Baker. He and Anthony Daniels (C-3P0) were the only two in all six movies (I think there was another extra that worked at LFL who played a stormtrooper, clonetrooper, and various other helmeted characters, but I can't remember his name). Today we are building R2's that do what we call 2-3-2 (2-legged to 3-legged and back again). These very few droids that can actually do this are very unstable, but we're working on it. Part of the fun of being an R2 builder is getting alot of inside scoop of behind the scenes stuff during all six shoots. I hope this little history lesson can help anybody out there who might have been wondering. Still, the cardboard R2 is pretty fantastic! I still like it! (might have to try this myself someday, maybe even try this technique on some WALL-E robots!).

[supitsgreg]

Looks totally awesome. Time to set it on fire! ^^

[lynellephi]

NICE! For a basic party prop, you're on the right track. LOVE the dome, nice paint job all around, nice use of found objects. It looks like you did some research on this. Now it's time to check out the official R2 Builders Club at www.astromech.net (free to join!). For anyone who wants to build a very accurate life-size R2, even out of cardboard (electronics optional). Blueprints, plans, drawings, advice, and the most wonderful forum on the web! About $99 for a very accurate plastic dome with base (salad bowls don't work, we've tried many). I would love to have you join us! After all, you are an R2 builder now...
Jawa Jaka and R2-AL
http://r2-al.blogspot.com

[Jon Ashley]

Great job! (And good shot-by-shot tutorial.)
Such a classic 'droid, I'm sure you'll use it many times.

[d.tzekakis]

great job!

[Ward_Nox]

that's cardboard. I DON"T BELIEVE IT :P

[Ten Thumbs]

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[mandyphillips]

I always wanted my own R2D2!

[colargolet]

Truly impressing job!
Adding wheels to the legs and the base of the body could make it movable.

[Scolova]

Great job, Look terrific!

[kea]

I think its great. I guess the painting would have taken the most time.

Just spraying cardboad with varnish will stiffen it. But wont add to strength, for that u need cloth reinforcing. Yep it will work with varnish as well as glass, though cheaper.
Cool 1 dude; Kiwi

[snoopindaweb]

=////=======> ~ Maybe the kind that gets slicker the more Ya' drag Yer' boat.? That Epoxy.

[Wasagi]

Amazing!!

[WoundedEgo]

Excellent job.

[Dandolion]

It looks fantastic. for the dome, you could, make strips of cardboard that fit between the ribs which would prevent the paper mache from sagging and mean less filling.

[jsgraham]

Granted you would have had to make the ribs and internals structure. However, why not use 2-5 oz fiberglass cloth impregnated with epoxy? 3 or 4 layers should do it. I've built several high power rocket nose cones using this technique. The nose cones get a lot more stress load than ole R2D2 would get. It would cut down on the weight at the top. Plus you can finish it with either Bondo or the same joint compound you've been using.

Kewl instructable

[elvis valentine]

Howdy,
that looks really good man.
If i may be so bold as to make a suggestion...
I reckon it could look better if you used some extra bits of cardboard/metal/junk for body detailing so that it has a bit more depth to it and maybe cut some bits out for that crazy 3D effect the kids seem to love these days.lol
Pretty hard to do after its made maybe but if anyone else gives it a go something to think about.
Really cool though for just a cardboard build. Great job!
E.V.

[artobot]

First off I want to say you did an awesome job! Seriously, it looks great. My one criticism though is he seems to be missing one of his feet.

[jetse]

You do know the 3rd feet is tetractable?.
but i agree on you he did do an awesome job

[Puzzledd]

This is excellent - I really like the way you explain the whole process, and the result is brilliant!

[Honus]

Your R2 looks great!

[timmy01]

......vary vary neato....++good

[Xolin]

That's excellent! Very clever use of basic materials and a clear and precise instructable - it was also nice that you commented on the problems.

[RavingMadStudios]

If you ever do anything like this again, those giant kid's bouncy balls (usually found for a couple of bucks in a net bin at department stores) make a great base for spherical paper mache forms, if you can find the right size.

[RavingMadStudios]

This is very very cool. Excellent work.

[CementTruck]

Awe inspiring.

[zhoramarg]

Hello

[NutandBolt]

Amazing job, I would love to make one. I was thinking in the past to weld R2D2 from scrap metal :-) Great ible

[jabronie25]

I love it! Haha