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    Water Rocket
    • Water Rocket Tutorial Index
    • Water Rocket Construction
      • Radial Deploy System

        Since it is the key to safely recovering a rocket and payload and all the time, materials, and labor that went into building them To insure the safe recovery of our fragile and expensive experiments and payloads, we decided that we needed to invent a parachute system that was more reliable than anything ever flown before. We dubbed this new design the "USWR Radial Parachute Deployment System", and it is a radical departure from traditional systems, because it relies on only one moving part. The system we designed met that goal and also has a number of other advantages over previous systems.This system is less expensive and time conuming to build, has less moving parts, and can be located more places on your rocket.

      • Axial Deploy System

        The objective of this tutorial is to demonstrate how to build a completely new type of parachute recovery system for water rockets. This system was developed to fill the need for a reliable parachute recovery system that could be made from common materials which was very easy and fast to make. Historically, ease of assembly and reliability have been mutually exclusive goals. This prompted U.S. Water Rockets to take a "clean slate" approach to the problem. This tutorial will explain how to construct the latest version of the U.S. Water Rockets Axial Parachute Recovery System.

      • Parachute

        A strong and reliable parachute design is very important to anyone wishing to develop a water rocket with a recovery system. Any system from a simple Air Flap mechanism to the sophisticated ServoChron™ electronic deploy system relies on a well made parachute. This tutorial will reveal the secrets to easily making a parachute that will safely recover your water rockets.

      • Bottle Splicing

        In order to create larger Water Rockets with bigger pressure chambers than afforded by typical soft drink bottles, many enthusiasts have resorted to joining multiple bottles together using various methods which all are commonly referred to as "splicing". This tutorial will show you how to use this new method to create perfect splices that are easier to create and outperform traditional splices in both strength and appearance.

      • Bottle Coupler

        This tutorial will show a method for creating inter-bottle connectors which can be used to join together multiple bottles by the threaded necks. These bottle connectors are useful for Water Rockets because they allow for a modular approach to be applied to your rocket design, which simplifies construction and repair of a damaged rocket.

      • Bottle Cutting

        Nearly every water rocket design that you can construct will involve some sort of bottle cutting. This tutorial will show you an easy method for getting perfect cuts every time.

      • Constructing Removable Box Fins

        One set of Water Rocket components which are critical to a successful and stable flight are the fins. U.S. Water Rockets designed and tested a new idea for creating water rocket fins which is called the "Box Fin" design, to create a quick and easy method for adding fins to Water Rockets which were much more rugged than typical fins, yet easier to fabricate with a higher degree of accuracy. This tutorial will explain how to create a triple box fin for a water rocket.

      • Enhancing Removable Box Fins

        The first improvement we will make is to modify the fin design so that it is adjustable to fit multiple bottle diameters. The next improvement we will make is to alter the attachment method for the fins. If you fly in an area prone to landing in trees, you can modify the design so that it will break away from the rocket with less force.

      • Nosecone

        One of the most important components you will build for your water rocket is the nosecone. This tutorial will explain how to build a good looking nosecone that performs great too.

      • Corriflute Recycling

        A relatively new building material used in the construction of water rockets is a corrugated plastic sheet or corriboard. It is also known under the tradenames of Corriflute, Coroplast, IntePro, Correx, Twinplast, or Corflute. This tutorial explains how to repurpose used corriflute for your water rockets.

      • Bottle Label Removal

        This tutorial will show you how to prepare your bottles for Water Rocket Construction. To prepare your bottles, the labels and glue must be removed, and the bottles must be cleaned of all contamination from their contents and oils left from manufacturing or handling.

      • Bottle Label Removal V2

        This tutorial will show you another method how to prepare your bottles for Water Rocket Constrction. This involves removing the labels and adhesive from the bottles and making sure there are no oils on the bottle. Failing to do so can result in the rocket leaking or exploding under pressure, due to contaminated splices.

    • Launchers
      • Cable Tie Launcher

        What good is building a water rocket if you have no way to launch it? The launcher we will be constructing is a variation of the Clark Cable Tie launcher, as this is the most reliable launcher that is easy to make.

      • Launch Tube o-ring

        Revised instructions for adding the o-ring to the Clark Cable Tie Launcher launch tube which simplify the build and improve the design. We have put a lot of effort into simplifying the design to remove steps which involve precise measurements and part placement, to maximize the ease of construction.

      • Cable Tie Release Mechanism

        This tutorial shows how to add a Clark Cable Tie Release Mechanism to the 22mm Launch Tube fabricated in the previous tutorial. This tutorial shows the newly revised and simplified instructions for making the release.

      • Split Collar Launcher

        This tutorial shows how to create the latest type of water rocket launcher which uses the newest improvements.

      • Gardena Launcher

        This quick tutorial showing how to make a compatible water rocket launcher that uses a gardena hose quick release connector for the release mechanism. This type of launcher also works with any standard gardena nozzle in addition to our 3D printed nozzle design. If you have all the materials on hand you should be able to build this launcher in an hour or less and be out launching water rockets in no time!

    • Electronics
      • Launch Detect Switch

        This tutorial will show you have to construct a very reliable and lightweight acceleration switch which you can use to activate electronic systems on your rocket such as a ServoChron™ Single/Dual Servo Actuated Parachute Recovery System.

      • ServoChron™

        The ServoChron™ is a low cost time delayed dual servo controller designed for use as a parachute deployment or staging mechanism for Water Rockets. There are other potential applications for the ServoChron™ as well. The core of the ServoChron™ is the Texas Instruments MSP430 LaunchPad. This $4.30US board is an inexpensive microcontroller hobbyist experimenting platform that you load our FREE application firmware into with a USB cable. The FREE ServoChron™ application firmware file created by U.S. Water Rockets turns the MSP430 LaunchPad into a user programmable dual servo deployment system timer/controller.

    • 3d Printing
      • Star Wars Droid

        U.S. Water Rockets is proud to release this nearly ¼ Scale accurate droid replica for 3D printing. This replica robot from the Star Wars Universe was designed to be the most detailed and accurate 3D Printable Astromech droid you can print, with exceptional detail lacking in other printable models.

    • Parachute Deployment Mechanisms
      • ServoChron™

        The ServoChron™ is a low cost time delayed dual servo controller designed for use as a parachute deployment or staging mechanism for Water Rockets. There are other potential applications for the ServoChron™ as well. The core of the ServoChron™ is the Texas Instruments MSP430 LaunchPad. This $4.30US board is an inexpensive microcontroller hobbyist experimenting platform that you load our FREE application firmware into with a USB cable. The FREE ServoChron™ application firmware file created by U.S. Water Rockets turns the MSP430 LaunchPad into a user programmable dual servo deployment system timer/controller.

      • Launch Detect Switch

        This tutorial will show you have to construct a very reliable and lightweight acceleration switch which you can use to activate electronic systems on your rocket such as a ServoChron™ 2 Dual Servo Actuated Parachute Recovery System.

      • Parachute

        A strong and reliable parachute design is very important to anyone wishing to develop a water rocket with a recovery system. Any system from a simple Air Flap mechanism to the sophisticated ServoChron™ electronic deploy system relies on a well made parachute. This tutorial will reveal the secrets to easily making a parachute that will safely recover your water rockets.

      • Radial Deploy System

        Since it is the key to safely recovering a rocket and payload and all the time, materials, and labor that went into building them To insure the safe recovery of our fragile and expensive experiments and payloads, we decided that we needed to invent a parachute system that was more reliable than anything ever flown before. We dubbed this new design the "USWR Radial Parachute Deployment System", and it is a radical departure from traditional systems, because it relies on only one moving part. The system we designed met that goal and also has a number of other advantages over previous systems.This system is less expensive and time conuming to build, has less moving parts, and can be located more places on your rocket.

      • Axial Deploy

        The objective of this tutorial is to demonstrate how to build a completely new type of parachute recovery system for water rockets. This system was developed to fill the need for a reliable parachute recovery system that could be made from common materials which was very easy and fast to make. Historically, ease of assembly and reliability have been mutually exclusive goals. This prompted U.S. Water Rockets to take a "clean slate" approach to the problem. This tutorial will explain how to construct the latest version of the U.S. Water Rockets Axial Parachute Recovery System.

      • Hybrid Deploy

        The Hybrid Deploy System is our latest idea for improving water rocket systems to make them more reliable and easier to build. This system improves upon our previously published designs known as the Axial Deploy System, and Radial Deploy System. By combining the ease of construction of the Radial Deploy System, with the heavy duty capacity of the Axial Deploy System.

    • Splicing
      • Bottle Splicing

        In order to create larger Water Rockets with bigger pressure chambers than afforded by typical soft drink bottles, many enthusiasts have resorted to joining multiple bottles together using various methods which all are commonly referred to as "splicing". This tutorial will show you how to use this new method to create perfect splices that are easier to create and outperform traditional splices in both strength and appearance.

      • Bottle Label Removal

        This tutorial will show you how to prepare your bottles for Water Rocket Construction. To prepare your bottles, the labels and glue must be removed, and the bottles must be cleaned of all contamination from their contents and oils left from manufacturing or handling.

      • Bottle Cutting

        Nearly every water rocket design that you can construct will involve some sort of bottle cutting. This tutorial will show you an easy method for getting perfect cuts every time.

      • Tornado Tube Coupler

        Many teams build their rockets in this manner using a pre-manufactured commercial product used in school science experiments commonly called a "Tornado Tube" or a "Vortex Bottle Connector". The commercial versions typically cost $1.00US to $2.00US each. This tutorial will show how to make them for pennies each and without the expense and time consuming process of turning them on a lathe. This method could also be applied to other size bottles such as the wide mouth bottles that sports drinks often are supplied in. These bottle connectors are useful for Water Rockets because they allow for a modular approach to be applied to your rocket design.

    • Creating Panoramas

      This tutorial explains how to create a panoramic view using some free image stitching software which you may already have on your computer and were not even aware of!

    • Tree Recovery

      If you have hobbies which involve things that fly, then chances are that you've had a project which you were flying end up stuck in a tree. We've had this experience a number of times in the past, and we wanted to share our Tree Recovery System with you so that you may benefit from our design. In this Tutorial we will show you how to build and how to use our design, which is easy and inexpensive to make and works amazingly well.

  • World Records
    • World Record Index
    • 2004
      • September 2, 2004 1,421 feet

        On September 2, 2004 U.S. Water Rockets set a new single stage water rocket altitude record with an average altitude of 1,421 feet, beating the old record of 1,242 feet that was held by Anti-Gravity Research.

      • September 6, 2004 1,471 feet

        Just 4 days after setting the water rocket single stage world record, it was raised to 1,471 feet.

      • September 11, 2004 1,481 feet

        After 4 more days X-10 set a new water rocket altitude record of 1,481 feet

      • October 23, 2004 1,606 feet

        On a beautiful fall day with the autumn foliage in full glory, the water rocket altitude was raised to 1,606 feet (stunning autumn foliage can be seen in the onboard videos).

    • 2005
      • April 16, 2005 1,609 feet

        On the first launch day of 2005 a new single stage water rocket altitude record was achieved. The required two flights averaged at 1609 feet.

      • May 26, 2005 1,696 feet

        This record was described on the television show Mythbusters.

      • September 24, 2005 1,715 feet

        The shakedown flights for the new X-12 water rocket proved to be winners with a new world record of 1,715 feet.

    • 2006
      • April 29, 2006 1,787 feet

        The freshly rebuilt X-12 water rocket sets a new world record after nearly being destroyed in an October 2005 crash during a record attempt.

      • April 30, 2006 1,818 feet

        After setting a record the day before, the weather conditions were conducive to another record attempt. A new record of 1,818 feet was achieved as the 2 flight average.

      • May 8, 2006 1,909 feet

        On May 8th 2006, a new WRA2 water rocket single stage world record was set by the famous X-12 water rocket.

    • 2007
      • June 14, 2007 2,044 feet

        X-12 pushes the official water rocket single stage world record to over 2,000 feet with an average of 2,044 feet.

  • Launch Reports
    • Launch Reports Index
    • 2004
      • 8-22-2004

        X-10 Water Rocket crashes and results in the total loss of a video camera and altimeter earlier today during a shakedown flight of a Water Rocket designed to set the World Record for Altitude. The launch went perfectly, but when the rocket went through apogee at nearly 1,200 feet it deployed a parachute which somehow separated from the rocket.

      • 9-12-2004

        A recovery crew for U.S. Water Rockets successfully retrieved the World Record Holding X-10 Water Rocket from a precarious position in a tree, where it had been lodged for 3 weeks. This flight insured the development of our tracking and telemetry system.

      • 11-23-2004

        The successful construction & testing of the remarkable new C-7 payload bay, the first ever payload section to loft a High Definition Water Rocket Video Camera

      • 11-27-2004

        C-7 is the highest resolution Movie Camera to ever fly aboard a Water Rocket, and was designed to outperform its predecessor, C-6 in resolution and framerate. In the second round of test flights, C-7 performed spectacularly, producing very smooth clear video with every test.

    • 2005
      • 6-5-2005

        The latest round of test flights which allowed ground observers to view and photograph a new design parachute in action. The entire deployment process was easily visible with binoculars from the ground, making the performance of the new system easy to evaluate. As a backup, in case the ground observations failed to produce conclusive performance data, we installed an innovative "ChuteCam" system in place of the WRA2 required Apogee camera. The ChuteCam uses a series of prisms to bend light and give the ChuteCam a reverse angle view, perfect for observing the parachute unfurling behind the rocket after deploy.

      • 10-29-2005 Crash

        While attempting to set a new WRA2 record altitude, parachute failure dooms X-12 and inspires herculean data recovery effort to recover the video from the destroyed camera.

    • 2006
      • 6-6-2006 2,001 Feet

        Although not an official record due to a second flight did not occur due to lack of daylight, X-12 becomes the first Water Rocket ever to surpass 2,000 feet.

      • 7-19-2006 2,088 Feet

        X-12 reaches an unprecedented altitude of 2,088 feet (636 m) on a clear summer afternoon with great visibility and bright sunshine. Unfortunately, when the rocket was recovered the water tight bulkhead seals of the payload section appeared to have cracked under the tremendous acceleration of launch and allowed water to fill the electronics bay upon splashdown.

    • 2008
      • 12-26-2008 Project 3000

        Launch Report of our X-12 Carbon Fiber High Pressure Water Rocket conducted to test our new HD camera and electronics payload during freezing cold weather conditions which resulted in a near disaster when the parachute failed, only to be saved at the last second by a tree.

    • 2011
      • 11-25-2011 7 Cameras

        Our B-2 Water Rocket was test flown with an unofficial word record of 7 onboard cameras in order to record video of a test of some enhancements to our free ServoChron Servo Deploy Timer Software, and our newly invented Axial Parachute Deploy Recovery Ejection System. This Launch Report contains the details of the launch and the results of the flight, including failure analysis and data logs.

  • Research & Development
    • Research & Development Index
    • Deployment Systems
      • Dual Deployment System

        The dual deploy system proved to be a resounding success and a quantum leap in safety. If either one or even both of the parachutes became tangled or failed to inflate, the separate rocket sections would be too unstable to fall ballistically to the ground. Instead, the sections would tumble slowly down, reducing the chance for injury or property damage on the ground due to a "lawn dart".

    • Launch Systems
      • Split Collar Launcher

        Water Rocket launcher mechanisms are an important area of Water Rocket design which has received almost no attention by researchers for more than a decade. This Research and Development article introduces our completely new launcher design to the water rocket community, and the history of the evolution of this radical new design.

      • Twist Lock Launcher

        The Twist Lock Launcher is designed as a low cost method to secure your water rocket while pressurizing. These plans are provided for free to anyone who wishes to use them.

    • Tracking & Telemetry Systems
      • Ground Test

        A rocketeers worst nightmare is a lost rocket, to combat this we designed our own telemetry and tracking system. A ground test of our new telemetry and tracking system

      • Live Test

        A live test of the tracking system proved a range of 50,000 feet.

    • Tools
      • Bottle Cutting Tool

        The bottle cutting jig will cut a straight cut around your bottles to remove the bottom or neck when splicing or making nosecones.

    • Pressure Tests
      • Compressor Failure

        To construct a world record water rocket, we needed to do many pressure tests. On this test the compressor failed and caught fire. Then the test vessel self launched at 300PSI!

      • Bottle Stretch Test

        Does a water bottle rocket explode because the plastic bottle heats and softens when the air inside is expanding and stretching the plastic? We wanted to find out. The purpose of this experiment is to determine if bottle burst pressure is reduced because of the heat generated by the stretching bottle as it expands.

    • Chase Camera

      As early as 2003, we were experimenting with ways to get outside views of our water rocket. Back then we had been flying a camera inside a payload compartment that was meant to separate from the pressure vessel at apogee. This article shows the development of a new system which would record the entire rocket for the entire flight, rather than just the descent of the pressure vessel.

    • 3D Camera

      At that time, basic ordinary video cameras capable of shooting 3D were quite costly (and they never came down in price since 3D never caught on in a big way). Therefore, we decided the only way to accomplish what we wanted was to build a 3D Camera Rig that would allow us to use our specialized cameras to achieve the goal. The way to accomplished this is to somehow use two similar cameras in tandem to capture photos and videos for each eye, and then merge them in software to create 3D output.

    • 3D Gardena Nozzle

      A type of Water Rocket launcher that has been popular for well over a decade uses a garden hose quick release connector for the launcher mechanism. These connectors are oftencalled Gardena connectors because of a popular brand of connector that these launchers and nozzles were made from. Constructing a launcher from a hose quick release mechanism is as simple as screwing the female section to a base and attaching a launch cord which will pull the connector latch open. We wanted to produce a large quantity of these nozzles for a school event, so we began investigating the effort that would be involved. The research we conducted convinced us that we would have to come up with a new way of doing things.

    • Tower Camera

      We wondered what the view would be like to a person standing on the tip of a Water Rocket as it was launched hundreds of feet into the air, so we came up with an idea to make a tower to mount a camera on the top of a Water Rocket, so we could find out what it would look like from that point of view.

    • Self Aligning Fin Brackets

      We put our new 3D Printer to use making our fin brackets, but there's no reason something similar could not be made from scratch using fiberglass, plastic, wood, etc. The 3D Printer just makes producing a lot of brackets as easy as pressing a button, walking away, and coming back later to collect the parts. Using this technology also allows us to configure the printer to print the brackets as hollow shapes, meaning that they are very lightweight.

  • MSP430 Launchpad Projects &Utilities
    • MSP430 LaunchPad Index
    • Projects
      • Replace Male Headers

        This tutorial will show a clever trick which will make it extremely easy for anyone of any skill level to remove the male headers that are installed on the MSP430 LaunchPad without damaging the circuit board, and replace them with the female headers provided.

      • Horizontal Stabilizer

        This tutorial shows how to modify your MSP430 LaunchPad so that you can use it with both Breadboards, and BoosterPacks. This simple modification is very easy and costs almost nothing. You can have the best of both worlds by adding these "Horizontal Stabioizers" to your MSP430 LaunchPad.

      • Ruggedizing the LaunchPad

        This tutorial shows how to modify your MSP430 LaunchPad so that the removable jumpers will not come loose if your MSP430 LaunchPad is subjected to high accelerartion or vibration forces. This simple modification is very easy and costs almost nothing.

    • MSP430 Drivers
      • MSP430 LaunchPad Drivers

        This archive contains the MSP430 Application UART driver file necessary to communicate to the UART on the MSP430 Launchpad. MSP430 projects which communicate to the PC will use this driver.

    • ServoChron™
      • ServoChron™ Manual

        The ServoChron™ is a low cost time delayed single/dual servo controller designed for use as a parachute deployment or staging actuator mechanism for Water Rockets, or Water Rocket Propelled Vehicles. There are other potential applications for the ServoChron™, but this document focuses on the Water Rocket single/dual parachute deploy application. The ServoChron™ was created specifically to make servo controlled recovery and staging mechanisms easy to build, and affordable or everyone. Note: this manual includes the ServoChron assembly, programming and operating manuals into one convenient file. This manual supersedes the previous revisions.

      • ServoChron™ Firmware

        ServoChron™ Firmware file archive for the MSP430 Launchpad.

  • Tips to increase performance & Altitude
    • Tips Index
    • Increase Altitude/
      Go Higher
      • Weight Reduction

        A lighter rocket will fly higher. Removing excess weight is one of the simplist ways to make your water rocket fly higher. This tip will show you how to make your water rocket, payload bay, camera, and deployment mechanism lighter.

  • LaunchPad AlTImeter
  • Manuals & Documentation
    • Manuals & Documents Index
    • Manuals
      • LaunchPad AlTImeter Manual

        Have you ever wanted to use an electronic altimeter to find out how high your rockets fly, but you have found that the commercially available altimeter products are too expensive? U.S. Water Rockets proudly presents the LaunchPad AlTImeter, a very low cost model rocketry peak recording altimeter with optional apogee detect output and servo motor control connection. With this "Do it yourself" project, you can save close to 80% or more of the cost compared to commercially available altimeter systems.

      • LaunchPad AlTImeter Firmware

        LaunchPad_AlTImeter Firmware file archive for the MSP430 Launchpad.

      • ServoChron™ Manual

        The ServoChron™ is a low cost time delayed single/dual servo controller designed for use as a parachute deployment or staging actuator mechanism for Water Rockets, or Water Rocket Propelled Vehicles. Note: this manual includes the ServoChron assembly, programming and operating manuals into one convenient file. This manual supersedes the previous revisions.

      • ServoChron™ Firmware

        ServoChron™ Firmware file archive for the MSP430 Launchpad.

    • Documents
  • Downloads
  • Water Rocket Resources
  • About USWR
  • Search
Member of the The Water Rocket Achievement World Record Association   Member since 2003

 

3D Printed Star Wars Droid Replica

Introduction:

U.S. Water Rockets is proud to release this nearly ¼ Scale accurate droid replica for 3D printing. This replica robot from the Star Wars Universe was designed to be the most detailed and accurate 3D Printable Astromech droid you can print, with exceptional detail lacking in other printable models. This project was inspired by some of the replica prop builds done by Adam Savage, featured on Tested.com and YouTube. The design was created completely from scratch, using reference stills from the movies and drawings available online produced by the R2 Builders Club (astromech.net). The design and build took place over the course of several months as a learning project to explore the limits of FDM 3D printing, and learn how to break down a complex design in order to print it with greater fidelity. A side benefit of this process is that it enables a much larger print to come from a small 3D printer. The downloadable files for the components needed to assemble this droid are avaialable on our Thingiverse page. www.thingiverse.com/thing:2290050 You will need to download and then print out the following printable components in the table below. These parts were created to fit in the 120x120x120mm print volume of the Monoprice Select Mini V2 and V1 3D Printer, but some of the larger parts of the legs will have to be rotated 45 degrees to fit the print bed. If you have trouble getting the parts to slice, you likely have a skirt, brim, or raft enabled, for which you will have to adjust the size of to allow the parts to completely fit within the volume of your printer. Below is the list of components and the quantities you need:
Gallery
PartQuantityPrinting Notes
Torso1Some Support is recommended
Dome1
Skirt1
Neck_Ring1
Center_Retract_Track1
Center_Retract_Top1
Center_Retract_Slider1
Center_Foot1
Center_Leg_Half2
Leg_Outer2Rotate 45 degrees to fit small beds
Shoulder_Hub2
Left_ Leg_ Inner1Rotate 45 degrees to fit small beds
Left _Shoulder1
Left _Foot1
Left_Battery_Box1
Left_Battery_Door1
Right_ Leg_ Inner1Rotate 45 degrees to fit small beds
Right_Shoulder1
Right_Foot1
Right_Battery_Box1
Right_Battery_Door1
HoloProjector3
Center_Vent1
Octagon_Port2
Power_Coupling2
Radar_Eye1
Utility_Arm2
In addition to the printed parts you will need to get a few screws and things to hold the print together. The fasteners used are:
PartQuantityUsed For
M3x25 Socket Cap Screw2Ankle Joints on Feet
M3x20 Socket Cap Screw2Shoulder Pivot Joints
M3x15 Socket Cap Screw2Leg Retract Top Cover
M3x10 Socket Cap Screw4Neck Ring attachments
M3 Nuts (Nylock type preferred)10For the screws above
1.75mm Filament1Used for alignment pins in many glue joints, and as Battery Hoses.

Note: Some of the assembly requires gluing pieces together. Glue appropriate for the type of plastic you have used for your prints will be needed. We suggest a good epoxy or CA Glue. Most of the glue joints in this design use alignment pins which you will cut from scrap 1.75mm filament, so have some extra filament handy.


Astromech Droids are available in a wide variety of colors. If you assemble this replica, feel free to print and paint this design in the color scheme that you like the most. There are many online resources available to help you choose a film accurate look to make this 3D Printed Droid an R2-D2 model, or create your own custom design. We chose to paint ours to look like the C2-B5 from the Rogue One film. Be creative!
Gallery
[Back to Table of Contents]

Part 1: Left and Right Leg Assemblies

Step 1:

Glue one Leg_Outer to the Left_Leg_Inner, cutting alignment pins from the 1.75mm filament piece and inserting them into the holes on the mating surfaces of the joint for alignment.

Step 2:

Glue the Left _Shoulder to the Left_Leg_Inner. Note that the shoulders have details which are specific to the left and right sides, so do not swap them if you want perfect accuracy of the droid. The Shoulder Button detail should be located toward the front side of the legs. .

Step 3:

Insert an M3 nut through the channel cut in the top of the Left_Foot, and slide the nut into the hexagonal cavity in the foot.

Step 4:

Insert a 25mm M3 Socket Cap Screw into the hole in the Left_Battery_Box, then through the hole in the inboard side of the Left_Foot. Get the screw to begin threading into the M3 Nut inside the foot. Slide the partially assembled Left_Leg into the channel in the top of the Left_Foot, and tighten the screw inside the Left_Battery_Box so it passes through the pivot hole in the bottom of the leg. Tighten the screw until it pulls the Left_Battery_Box tight to the Left_Foot.
Gallery

Step 5:

Snap the Left_Battery_Door over the screw in the Left_Battery_Box. Press hard until it snaps in.

Step 6:

Using spare 1.75,, filament, create the two Battery Hoses that run from the Left_Battery_Box to the Left_Foot. Cut and bend the filament to fit, apply glue and insert into each hole.

Step 7:

The Left Leg is now fully assembled. Repeat steps 1 through 7 for the Right Leg assembly. The completed Right Leg assembly should be a mirror of the Left Leg assembly. [Back to Table of Contents]

Part 2: Assembly of the Center Foot and Retraction Mechanism.

Step 1:

Glue the two Center_Leg_Half parts together, using more cut 1.75mm filament pins for alignment.

Step 2:

Snap the Center_Foot on the bottom of the assembled Center_Leg. The two bumps on the bottom of the Center_Leg will engage into holes in the sides of the channel on top of the Left_Foot and become a pivoting joint.

Step 3:

Slide the Center_Leg_Slider into the Center_Retract_Track. The side with the cutouts for the Center_Leg faces the rectangular side of the Center_Retract_Track. Work the slider up and down to make sure it slides easily.

Step 4:

Use two M3x10 socket cap screws and M3 nuts to attach the Center_Retract_Top to the Center_Retract_Track..

Step 5:

Glue the Center Leg assembly into the opening in the Center_Retract_Slider. These parts are symmetrical, so don't worry about which side is the front or back.

Step 6:

Glue the Skirt onto the rectangular end of the Center_Retract_Track. [Back to Table of Contents]

Part 3: The Torso:

Step 1:

Glue the two Octagon_Ports to the cutouts in the lower Torso.

Step 2:

Glue the two Power_Coulplings into the cutouts in the lower Torso.

Step 3:

Glue the two Utility_Arms to the cutouts in the upper front of the Torso, using 1.75mm pins for alignment.

Step 4:

Glue the Center_Vent into the cutout in the front of the Torso. [Back to Table of Contents]

Part 4: The Dome:

Step 1:

Glue the three Holoprojectors into the circular cutouts in the Dome. The projectors can be rotated before the glue sets to produce a desired pointing position.

Step 2:

Glue the Radar_Eye into the cutout in the front of the Dome. [Back to Table of Contents]

Part 5: Final Assembly:

Step 1:

Push four M3 nuts into the hexagonal cutouts under the top lip inside the torso. They should snap in place and be held captive so they don't fall out or need a wrench to tighten.

Step 2:

Use four M3x10 screws to attach the Neck_Ring to the top of the Torso.

Step 3:

Push two M3 nuts into the Hexagonal cutouts inside the Torso at the pivot points where the legs attach on each side.

Step 4:

Use two M3x20 screws to secure the Left and Right Legs to the Torso. Do not overtighten the screws, otherwise the legs will not rotate at the shoulders.

Step 5:

Snap the two Shoulder_Hubs into the holes in the Left and Right shoulders covering the screws holding the legs on. Do not glue the Shoulder_Hubs, so you can remove them later for maintenance on the shoulder screws.

Step 6:

Slide the Center Leg assembly into the bottom of the Torso. The Skirt will snap into the bottom of the Torso at the perimeter. Do not glue this in place if you wish to be able to perform maintenance on the leg retraction slider mechanism.

Step 7:

Push the Dome on top of the Neck_Ring, and it will snap in place. [Back to Table of Contents]

Congratulations! You're done!

Finished Droid Gallery
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Creative Commons License 3D Printed Star Wars Droid Replica Tutorial by U.S. Water Rockets is licensed under a Creative Commons Attribution-NonCommercial 3.0 Unported License.