March 14, 2004

I used my R2-D2 Telephone as a guide and just scaled up the measurements to life size proportions. The body was an easy step since it is just a hollow tube. I cut 2 rings, in the same circumferance as the dome, and taped cardboard all around. The seam in the back, even though he would be covered entirely in tape and it would not really show.

The bottom end was completely closed in. I used a ring on top to access the inside if need be. I cut 2 holes on the opposite sides to stick the "pin" that would fit into the legs. The "pin" was made in the same fashion, 2 end circles with cardboard taped all around till they joined at the seam. I also penned in details of R2's panels to make sure the proportions were correct before cutting into the cardboard..

March 14, 2004

Next came the bottom detail. I decided NOT to make a center leg. Yes I know, call me lazy - LOL. I just scaled up the phone measurements again, cutting out the proper shapes and taping everything together. For the groove details on the side, I cut 1 inch strips and just taped those on top of the base shape I had created. Adding on top of is easier then carving out :)

March 17, 2004

Now I had to make the details that fit on the outside of the leg. This also makes the leg thicker and more sturdy. The first piece looks like a horse shoe and easy to make. The other was an extension with a curved end and a little V shape detail.

March 17, 2004

Here is a better picture of the legs pieces. You can easily see the "L" shape bottom end and the grooves that are in the base shapes. My cat Fingers is not part of R2 :)

March 17, 2004

Here is the leg with the inner layer if you will, with the Horse Shoe shape and outside detail taped all together. I did this on both legs before adding the 2 final details.

March 17, 2004

Next came the legs. You can see how the "Pin" fits into the legs slot to keep R2 standing. If you notice on R2, his legs have 2 layers. this is this inside layer. I cut out the profile shape 2 times and then joined the pieces using a long 2 inch strip of cardboard and tape. The bases were like making a shoe box but angled and with a curve on the inner side.

Oh if you look at the picture, you can see there is a "L" shape joint at the bottom of the leg so that it fits perfectly in the groove oh his base. In case I ever decide to add a 3rd leg and have the sides pivot. :P

March 17, 2004

This part was kinda tricky but the tape hides all the defects in the joints - hee hee. First I had to make the Half Moon shape bottom detail on the leg, including what looks like a giant screw or some metal object. Then I had to make the Box with round ends that fits on the inside of each legs bottom foot. Again it's just like making a shoe box but with rounded corners.

I made 4 holes and poked plastic tuning inside. Bike pump hose would look better I think but was too expensive.

March 25, 2004

Now for the long and boring part of making R2. 12 hours etching the details of his panels! After drawing all the outlines with a pen, I used a sharp Xacto blade to break the carbord outer surface without poking completely through. The cool thing about corrugaded cardboard is that there are 2 layers with a wavy interior (to give it thickness).

Peeling out the wavy middle made a fragile but amazing and accurate embossed groove detail. The pieces that were to be hollow were completely cut out. Now our fave Droid is coming to life :)

I decided to cheat and get a peak at what he looks like so far so I stacked all the pieces together. At least the proportions are correct - LOL. Now I started to cover every inch of cardboard with tape. Going into each little groove and reinforcing the cardboard. The tape also allowed a uniform texture to R2 as well as a surface that the paint would not warp. Cardboard and water don't really mix that well :P

March 25, 2004

I used the "orange slice" technique. You know how each slice when joined together forms a sphere? I made 7 divisions of half circles and inserted them into each other. Then cut out pizza slice shapes that I taped inbetween each slice. You can easily make out the sections in the picture as it is not perfectly round. I tried placing plaster on top to smooth it into smooth dome The horror - LOL - it did not stick and cracked because it was too thin. I used a pen to draw the detail shapes I would need to later cut out to complete R2's head.

March 25, 2004

Time for Dome details. The grooves in the dome were harder to make because the way it way created. All patches of cardboard as opposed to 1 singled piece for the body. I also had trouble getting the good shape for the protruding plate that the eye bubble fits into. After 4 tries I got it right. Then I covered the entire dome with tape.

March 28, 2004

After making all the tiny grill details and coin slots on his front I was ready to paint. I started on his head and let that dry to see if the paint would affect the shape and sog up the cardboard. Even though I used a metalic silver car spray paint, it did not get a metalic glossy look :( But it still turned out cool and the cardboard did not warp :)

March 28, 2004

I painted the entire body with white and blue latex house paint. It's amazing what color does to it don't you think?

Here is a close up of the top part.

March 28, 2004

Here is a close up of the body. I am sooo happy with the outcome I have to try and make a cardboard 3P0 one day. Plus I have the satisfaction of telling friends I made him and saved $10,000. Ha ha Don Post. LOL.

March 28, 2004

Finally a close up of R2's Feet.

If you want to see more pictures of My finished R2-D2 just Click Here to warp to the NiubNiub Archives Section.

March 28, 2004

Here is the finished painted R2. Sorry to have to make you tilt your head sideways :)

If you made yourself a lifesize star wars item, send me pics, I would Love to hear from you. Maybe you will even inspire me in my next creation :)