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GUESS WHAT KIDDOS…. WE FINALLY FINISHED THE RHYS ROBO ARM TUTORIAL! NOW LETS GET STARTED

Use this tutorial for any robo arm-ed badass (or in Rhys's case Hyperion-office-monkey-wimp).

MATERIALS USED:

  • Worbla (or Wonderflex) (about 1 and a half sheets of XL)
  • Craft foam
  • Foam board
  • Exacto knife
  • Scissors
  • Wood glue
  • Toilet paper roll (for the elbow)
  • Gesso
  • Acrylic Paint
  • Elastic straps (black)
  • Velcro (black)
  • Tons of fast drying super glue
  • Lights (I got my lights at Adafruit.com) (blue lights:LINK Red Lights:LINK)
  • Soldering iron
  • Copper wire Clear plastic (I used plastic from a clear storage box lol)
  • Sandpaper
  • Paint pens (black and white)
  • Matte spray Sealant

Step 1:

Download and print the PDF [LINK] (pdf includes printing instructions & actual sized patterns for each piece)

I REPEAT, THE PDF IS ALL THE HARD WORK DONE FOR YOU! IT INCLUDES THE PEICES FOR THE ARM IN ACTUAL SIZE WHEN PRINTED ON REGULAR PRINTER PAPER! (8.5 X 11) :)

Step 2: Cut Out Patterns

Cut out patterns. Because the pattern is fit to my arm, it may not fit your arm perfectly. Therefore make adjustments where needed.

*****Note that I have not included the shoulder or the fingers. That is because those pieces will need the most modifications to fit you. See picture to see what the basic shape of the fingers will look like… (one piece of worbla… so no craft foam or sandwiching)

Step 3: Transfer

Transfer the paper patterns from the pdf to craft foam and cut out.

Step 4: Worbla

Now the fun part - WORBLA (or Wonderflex)! Sandwich the craft foam in worbla. (If you don’t know the Sandwich method then please refer to Kamui’s Worbla tutorial [ LINK ]

****Elbow piece is a little different because instead of using craft foam as a base… you will use a toilet paper roll… cut to fit your elbow and cut open to fit your elbow inside. Cover the roll in worbla. Unfortunately I forgot to take a picture of it until it was finished because I’m a hot mess.

Step 5: Re-heat Pieces and Fold

After the worbla is sandwiched and extra on the edges is cut, Re-heat the piece and begin folding along the lines. Let cool to keep shape.

****If you are adding lights… make sure you cut out the pieces where you want the light to shine through (on forearm and upper arm).
****Also on the forearm you will notice that there is a piece that bumps out of the arm with a blue and red light. That is the only piece that requires the use of the clear plastic. Cut the plastic to triangular shape + small square for red light. Sand pieces so that when the light hits the surface… the light fills out the space. Glue piece to worbla and finally to arm piece…. MAKE SURE TO ADD THE LIGHTS IN BEFORE YOU GLUE TO FOREARM! We provided an example of the clear plastic before and after sanding to give it that clouded look so the light distributes properly.

Step 6: Priming

When all pieces are assembled. Apply 2-3 coats of wood glue. Then 2 layers of gesso (sand between each coat). As you can see below each of the pieces are at different stages of coats.

TIP: If you decide to use lights in your robot arm, a great place to hide the battery pack is in the bicep piece! I WAS ABLE TO HIDE 2 OF THEM IN THERE YEAHHHH


****unfortunately you are going to need 3 battery packs because the red sequins (you need 2) need separate battery packs or else the light won’t be as bright. unless you can find a battery pack that can power both sequins at full power.

Step 7: Painting

After all the pieces have been properly coated with wood glue and gesso, you’re ready to start PAINTINGGGG. This part is pretty simple, just add a few coats of acrylic paint (yellow) with a bit of white to make it look kinda uneven and worn or whatever. Add white stripes where needed (use painters tape to keep lines straight). Dirty up with watered down blacks and brown acrylics. And finally cel-shade with paint pens (along every edge).

Step 8: Seal It

Seal with MATTE sealant (this is important because if its a shiny sealant it takes away from the cel-shaded effect!)

Step 9: Wiring

When it comes to the lights, I always make sure to install all that wiring last, makes it easier and you don’t have to worry about getting paint on everything, but don’t forget to make sure the lights are working properly!

Because scrolling up to the top of this post is probably a pain by now, I’ll just repost the links to where I got the lights
I always get my lights at Adafruit.com.

BUT WHAT ABOUT THE BATTERY PACK?!!!?
shhhhh its okay the links take you to a starter pack, so it comes with everything you need baby (with the exception of a few extra copper wires for soldering the red sequins) Blue Lights: LINK Red Lights: LINK

Step 10: Finish It

Grab a shirtless ab-tastic sidekick (or whoever you have available) to help you size the piece onto your arm with elastic straps.

****For fingers you will only need to attach with the glue the top fingers to a black glove (make sure you have all the parts of the finger on before gluing! And careful not to glue your fingers to the glove! As for the palm… attach black fabric to the back of the worbla and use the fabric to sew the piece to the glove.

Step 11: BRO-FIST YOUR BRO!

AND LASTLY BRO FIST YOUR BRO BECAUSE NOW YOU HAVE AN INSANELY COOL ROBO ARM TO MAKE ANY HYPERION JEALOUS!

Feel free to message us if you have any questions! And bro, share any progress with us because we’re bros, bro!

About This Instructable

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Bio: Master level cosplay sister duo Labinnak & Mangoloo Cosplays (and Shirtless Mike) have been creating costumes and props from scratch since late 2013. Using knowledge from ... More »
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