You will need
1 x Willow Bullet bin (@$30 for the big one)
2 x cans of primer and flat white spray paint
1 x can of bright chrome spray paint
1 x sheet of 1.2mm mdf
1 x clear Christmas decoration
2x A4 photo paper
10 x paint sample cards
Glue - pva and some contact cement.
Camping mat foam.
So into the spray booth it went (under my house). Primed and then painted with satin white and chrome for the dome - about 3 coats each.
Then I found an awesome high quality paper craft version of R2D@ and enlarged it and cropped it, then printed the front panel onto photo paper and glued it into place.
Then using the paper craft file as a reference I found some matching paint cards from the bunnings store and cut them into the wedges and rectangles I needed for the dome.
R2's eye was made with foam camping mat- great for compound curve of the dome. painted with PVA glue and the painted with gloss blue paint. the lens was made with a clear Christmas decoration, hacked to size with a dremal, with black sprayed on the back to keep the shiny stuff... um shiny.
Legs were a bit of an issue - I tried thick card over balsa wood, but that didn't look so good. so I went back and did the legs out of MDF. - Glued together and then painted - I then went over the sawn edges with styrene and a heat gun and glued them on.
Feet are definitely not regulation - they are just plastic storage bins upside down with holes cut in the top.
Improvement to finish and fix.
- shoulders - probably some big mailing tube will do the trick.
- needs two projectors - powerade bottle tops painted silver look to be a cheap option.
One day I'd like to make a more accurate R2, but for the moment Bin2 will do fine.