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03.06.17

Well, it’s been a little over a month since I’ve updated Wheatley’s Work Log. College has been hectic and has kept me pretty busy, but this week is Spring Break! I finally have some time to work on Wheatley!

I’ve been sanding and dremeling away whenever I get a chance. Due to a design flaw, I had to remove a segment of plastic from the back of the Faceplate. This was rubbing on the Upper Eyelid. It still kinda rubs, but not as bad as it used to. I also had to remove a bunch of material where the servos go. I based my design on RadioShack Standard servos, but I found out later that the term “Standard” doesn’t mean “everything labeled Standard is the same size”. It really means “everything labeled Standard is mostly the same size”. I bought some cheaper but higher-quality RAGE metal gear servos which ended up being slightly larger than what had been printed.

The Inner Socket has gone through a few changes too. It’s been sanded down to almost smooth, despite the layer gaps on the top and bottom. The back of the Inner Socket has been cleaned up considerably thanks to my trusty dremel. The shaft on the inside had to be replaced with a wooden dowel because it broke. It just wasn’t strong enough to hold everything. I also removed material to accommodate for servos.

The Sides have been sanded down and evened out. I had to remove some material for the Handle’s movement mechanism, which got a redesign itself. The Traxxas Half Shafts were taking up too much space, so I resorted to a geared assembly made of LEGO pieces. Since LEGOs are made of ABS, they will bond perfectly to the Sides.

The Eyelids sanded down very well. They’re so smooth! Also, the Handles look a lot better after being sanded. However, they have quite a few holes that need patching (but we’ll address that in a moment). The Gimbal Mount also needed to have material removed to accommodate the larger servo. The only modification I’ve made to the Gimbal itself was to drill out the holes so that the screws fit (I also did that to all the parts that have screw holes).

I’ve heard good things about Apoxie Sculpt and have seen other people use it in their projects. So, I decided to buy some. It can be pricey as well as hard to find, but Amazon.com had this sample pack for $8-9. The next phase will be to apply the Apoxie Sculpt to all the areas that have holes, need to be built up, or patched in some way. I’ll consider these the “Before” pictures, and the next update will have the “After” pictures. Wish me luck!

More Pictures and Details Here