Two click lights or Lids of some kind for eyes
Two plastic bowls
Sports equipment (shoulder pads, leg pads, helmet, faceshield, snowboard bindings, kneepads)
scrap thin wood
fur (yellow and brown) half yard yellow, 4 inches brown
pooh stuffed animal
Two old computer Mice
tent window mesh
3 cans silver spraypaint (optional gold and blue, green)
needle and thread
ffew dozen nuts and bolts washers, assorted screws
cheap masquerade mask
small angle brackets
yard of 1" dowelling
small doweling for connections (or a chopstick or two)
Several wooden cup shapes with 1" holes (I got at surplus cupboard handle store)
wooden wheels or equivalent
dollar store plastic toys for nuts and bolts
some wired object for the tail (i used a long stuffed animal type flower)
goldfish stuffed animal or equivalent
pipe clip or piece of tin
cheap mount climbing rope clips or keychain clips.
drill (small bits and 1" bit)
cost at thrift store prices <$200
Step 1: Building Clank
When you attach him, make sure he sits straight up and down and low enough for you to move your head back without hitting HIS head. His feet should not ride on your butt or the will break off, so they must be fairly far forward.
Step 2: Clank's Body and Head
I used two dollar store bowls for the head and jaw. The kind I got were a hard glass-like plastic, that fractured when I drilled the holes for attaching the eyes, main support, and neck, so be careful what you get, closer to tupperware would be best, thick but not brittle. I needed them to be hollow to get to the eye batteries but if you don't need that you can use something the right shape that is solid.
Sand everything smooth and spraypaint it on a sunny day in thin coats.
Step 3: Clank Head, Eyes, Neck
To keep the bolts of the eyes accessible I had to allow access inside the head, so I stuck the two bowls together with a really long bolt that I was hoping would go all the way through, but was a bit short so I added a new support inside and kept the butterfly nut on top of the head for easy access. This mistake turned out to be usefull, since it was not in the way of the neck attachment then (yay for poor planning that helps!)
The full head was screwed onto the dowel (always use washers) through all the plates and the hole in the bowl (always predrill)
For stability of the bowls and because they seemed to crack easily, I make 2 circular plates out of 1/4" thick wood paneling ( actually the wooden back of an old tv I think) that I bolted together through the bowl itself, and the spacers for the long butterfly bolt, and IT'S small plate. See diagram.
The neck was about a foot of 1" dowel (that turned out to be Hardwood, which was really difficult to drill and screw, BUY SOFTWOOD if you can.
I later added some "bolts" to the side of his head, that I should have drilled at this step.
Step 4: Clank's Airvents
Attach this first since it is the hardest to get to, and you don't have to deal with the fragile arms and legs or neck.
Clank has a small black box between his legs too. I found a black soap dish box and bolted it on at that time as well.
Step 5: Clanks Legs
Two 3" -ish long wooden dowels made the upper and lower leg bits. They were screwed and glued together. Cut the ends off at 45 degrees so the legs dangle bent on the body
I used computer mice for feet (empty the electronics, wheel and cord out) which were already grey and black, i sanded and painted over the dell logo. The hole where the wheel goes was in a useful place so a small hole in the bottom and they just screwed onto the dowel.
The screw on the top went through the bottom of the body and they held firm.
Step 6: Clank's Arms
So the basic construction is hand, forearm, cup, upperarm, wheel, body. I put a long screw from the inside of the body through the wheel and the upper arm. Make sure you predrill that angle correctly. I did it wrong 6 times and had to get more 1" dowel and recut and repaint it all, which cost me a whole day. Doh!
The screw was long and allowed the arm to swing. Make sure you put a washer on the body inside plastic is in fact "plastic" and screws tend to pop through if you pull them, after a while. The swinging turned out to be a good idea since i banged them on doors a lot. This would also be useful in a bar with idiots who will grab his arms first I am sure. (covering them with thumbtacks would be a good preventative measure)
Step 7: Clank's Neck Onto the Body.
After humming and hawing for a few days, I discovered some hard building block foam I had gotten at at garage sale that was 2 inches thick. I was planning on just drilling holes through several pieces and then gluing them, but when playing with that one got stuck when I put it in sideways! Eureka!
I just used a couple of pieces that were cut exactly to bridge the sides and since it was slightly flexible, I could get it in and it held really tight.
I also got lucky that I had just inherited a bit and brace that happened to have a 1" drill bit. (Thanks Grandpa) The bit was antique of course so it wouldn't fit in my new handdrill, so I used the bit and brace itself. The bit and brace was REALLY comfortable to use and worked better than my new drill, it didn't skip or slide around, it just dug in and held where you put it, nice and slow. Cool experience, and Environmentally friendly too!
Step 8: Attach Clank to the Backpack
The mailbox didn't have many nice attachment points at the bottom, so after drilling and bolting the backpack to the top into two holes, (put washers on the backpack side too), and making sure it sat straight, and measuring where the bottom bolts should be. I decided to put two more angle brackets onto the bottom of the base of the body. I just bolted the pack bottom to them (behind his leg)
Test it out to see if it sits straight, and doesn't interfere with anything.
Step 9: Weapons: Sonic Eruptor/ Burp Gun
When looking for the correct creature I actually found a goldfish stuffed animal on the first try at shopping. It was expensive but I couldn't pass it up. Finding a Nerf gun turned out to be the harder thrift store find but I got one at the last minute.
I took out all the unnecessary guts from the gun to make it lighter (no longer shooting rockets...sigh) but looked about right, and was the right colour too.
I just wired the fish right to the frame in a few minutes.
Step 10: Weapons: Ratchet's Wrench
Having experience with long wearing of costumes, I knew I had to keep one hand free, and I had a wrench and a gun, so I decided to attach the wrench to some loops onto two mountain climber rope clips I got at the dollar store onto my pant belt buckle loops. This let the wrench hang in a convenient spot while I did other things and i didn't have to keep setting it down. The straps I used were long enough that when the papparzzi were taking pics, I could grab it and hold it out a bit, and look like it wasn't hanging but being carried, then i could drop it again and carry on walking around.
Step 11: Ratchet's Armour
I ripped the padding out of some old hockey pants for the hip and tail armour, I had some old kneepads, I then got lucky on some snowboard bindings to make silver hover boots that I stole for 3$. Everything got spraypainted silver which ate up 2 cans of silver spray paint.
I added some blue sections to the chest part, with some paint i had.
I used a batting helmet with the brim cut off, with a hockey visor for the helmet.
Step 12: Ratchet's Tail
I had gotten lucky and found a close out sale of GLAM TRIMZ which was various shades of yellow 3" wide strips of fur trim. I got a few inches of brown fur at the same place for decoration.
I didn't have any longer fur, for the tip and was running out of time so I sacrificed a frufru style dog stuffed animal from a gift store just for the fur. It was a satisfying murder (I hate yappy old lady dogs -- well not my definition of a dog really, if you step on it and it dies, it wasn't a dog anyway it was a glorified rat)
I got lucky on the flower colour and used the petals for the cheeks of the sonic eruptor goldfish. later i cut off the entire flower head and bolted the wire to the butt armour.
The tail is posable.
Step 13: Ratchet's Mask Structure
I wore the head to see where my eyes were and cut the holes there. After a round about experiment painting 2 magnifying glasses as eyes, i hated them and couldn't see, so i re-engineered the eyes using flat fun foam from the dollar store (like construction paper but thin foam for kids crafts) For the pupil I used tent window mesh which is both opaque black from a distance and invisible at short range. so you can see out but hey can't see in. very useful. I cut out some nice cartoon eye shapes with highlights. They didn't have green foam so i painted some blue foam quickly and it worked out fine. I hotglued the foam eyes on and it worked great. I had lots of vision, but wearing glasses is still a pain, since the tend to fog up on a hot summer day. Halloween should be better.
Step 14: Ratchet's Face Teeth, Eyebrows
The teeth were a long strip of funfoam cut out with teeth part way through. I stuffed them up under the allowance of the gumline fur and hot glued them there to the fur. (top and bottom). He looked funny, and although ratchet doesn't seem to have lips in the game I rolled a thin strip of the fur material inside out and put a roll of it on the bottom gumline. That made it much better and gave him that weird grin that ratchet always has.
Really funny thing, without the nose you would swear it was a homer simpson mask. yet another visual cue humans can't get over.
Step 15: Ratchet's Ears
I was half hour from leaving deadline with no sleep and couldn't figure out how to actually attach them to the helmet. Then almost giving up, I found a masquerade mask that I was originally going to use to structure the face. I cut it in half and used 2 angle brackets to bolt it to the helmet. I folded the ears around the triangles of the mask uprights and they held pretty well, since the mask was wavy. I took some wire and clipped the corners of the ears together really tight and the waviness of the mask held the ears firmly in place. The flexible plastic of the mask let the ears bang around and flex without tearing off.
Step 16: Gold Bolts
I was planning ot make space gloves for him including the Groovetron disco ball, but I ran out of time, so I used my trusty antique motorcycle gloves that I wish I had 100 pair of, since they are so useful.
I had lots of fun at Anime North in Toronto, and everyone seemed to want to take pictures. Hope you had fun reading this too.