The back of the legs were a complete mess after removing the raft. I started with a generous coating of wood filler and sanded until they were nice and smooth.
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I filled all the seams and gave them many coats of primer.
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I wish I took a picture of what the backs looked like before I smoothed them out. You would not believe the difference.
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I then gave them several coats of white. I wish I took a better picture of them.
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Now for the greeblies. I started with the ankle bracelets. I gave them a few coats of primer.
I then painted them black and gave them a coat of gloss.
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Finally, I painted them silver. It's amazing how even such a simple part like this can take so long to complete. You have to wait until one side is completely dry before flipping it over and doing the other side. After 8 coats of paint, a part like this can take all day.
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I then attached the bracelets and the ankles to the legs. With such a tight fit, I didn't even have to use glue. If I ever need to make repairs, I can easily just pull them off.
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Back to the greeblies! The knurled bits are actually for the battery boxes and feet, but I forgot to paint them before so I figured I'd do them all together.
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Since these are all resin and the surface is so smooth, I didn't bother priming them. I painted them black, gloss, then silver.
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The booster covers came out with a lot of layer stepping since the top surfaces are at an angle. I sanded them as best as I could, lathered them in a layer of wood filler, then sanded them smooth.
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I was not happy at all with how the leg struts looked in PLA. It would be almost impossible to sand them smooth in those hard to reach places. I reprinted them in resin. The difference in quality is night and day.
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You know the drill… black… gloss…
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…silver.
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I think I dumped a whole can of primer on these until I was happy with them.
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I then gave them a few coats of blue.
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I masked off the blue areas and painted the details silver. When I removed the blue tape, it took some of the silver with it. Bummer.
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I took a Q-tip and went back in with some Ruff 'n Buff. They came out perfect.
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These guys just got a few coats of primer and some white.
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The last piece to do are the horseshoes. The PLA prints came out terrible. Just like the center foot, the top layer was thin and they were crunchy when I squeezed them. They also lifted off the bed a little at the ends causing a visible gap when connected to the legs. Not to mention the print defects around the inner areas would have been almost impossible to sand out.
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I decided to recreate them in SketchUp using 1/8" layers that I could laser cut out of MDF and glue together.
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I hollowed out the inner layers as much as I could in order to keep the weight down. I then exported all the layers out and cut them on my Glowforge.
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I included alignment holes so that I could hold them together with screws while the glue dried.
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With crisp sharp edges, these look so much better than plastic prints.
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I then gave them a few coats or primer.
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It's going to be tricky getting white spray paint in the tiny little recesses and corners so I went in with a brush and some white acrylic just to get some color in there.
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After I primed them, I remembered that the bottom of one of the smaller holes is actually at an angle so I took the pieces that were cut out of the holes (glad I kept them) and glued them in at an angle. I then gave them several coats of white.
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The edge of the back layer is actually painted silver. I imagine if I had glued the whole thing together, it would have been a pain to mask off the entire horseshoe in order to paint that tiny little strip of silver. I decided to not glue that back on so that I could paint it silver separately, then glue it on when it was done.
I painted them black, gave them some gloss, and then painted them silver.
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I then glued them to the back, glued in the magnets, and screwed in the greeblies. They came out awesome!
It's time for the finally assembly! I glued in the magnets and started to install the greeblies.
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I then installed the boosters and struts, and finally the horseshoes. I am so happy with how they came out. They look amazing!
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It took six months to complete the dome and the body, but only two months to complete the legs. I thought it would have taken longer, but the weather has been good to me so I've been able to get a lot done over the past few weeks.
See this project from start to finish:
3D-Printed R2-D2 - Part I - Dome 3D-Printed R2-D2 - Part II - Body 3D-Printed R2-D2 - Part III - Skirt 3D-Printed R2-D2 - Part IV - Body Assembly 3D-Printed R2-D2 - Part V - Body and Dome Finishing 3D-Printed R2-D2 - Part VI - Body and Dome Greeblies 3D-Printed R2-D2 - Part VII - Final Dome Assembly 3D-Printed R2-D2 - Part VIII - Legs and Feet 3D-Printed R2-D2 - Part IX - Foot Drives 3D-Printed R2-D2 - Part X - Center Foot, Ankles, and Battery Boxes 3D-Printed R2-D2 - Part XI - Legs
3D-Printed R2-D2 - Part XII - Foot Shells and Final Assembly 3D-Printed R2-D2 - Part XIII - Doors and Charging Bay Indicator and Data Port Logic Lights 3D-Printed R2-D2 - Part XIV - Interface and Gripper Arms