body

THE SKIN

Using blueprints I got from the R2 builder's club, I converted the prints to a format that a sign shop is capable of using. I then had the sign shop make a full size template for me, and I had to cut the skins out by hand.

The skin is made from 2 layers of a product called KOMATEX, it is the same as SINTRA, a PVC breed of sheet plastic used for making signs. It is relatively inexpensive product.THE SKIN LAYERS ARE ILLUSTRATED BELOW.

You will need:

1 sheet 4 ft. x 8 ft. of .04 thick material. I used KOMATEX or SINTRA (a PVC breed of sheet plastic). Styrene, Aluminum, Posterboard, can all be used. This will work with whatever Route you are going to use.

A method of cutting out shapes in the material. In my case a simple XACTO knife and a ruler were all that was needed.

Glue. Something to bond the layers of skin together. For KOMATEX or SINTRA I used all purpose plumbers glue for PVC pipes. This provides a great bond.

The attached picture shows how my layers of skin looked before putting them on. You will need to layout the skin pattern completely before cutting anything. Both layers should fit on one 4ft. X 8ft. sheet.

LAYER 1 (THE SUB LAYER)

This is the under layer, the first layer you will attach to the body. I have 7 door cut outs shown. NOTE: These cutouts (1-7) should be smaller than the actual door. This gives the door something to rest against when closed.

If you are not planning on having opening doors, than you don't need to cut out areas 1-7.

All the "poke thru" details have been cutout except the three coin returns and the two silver vents with recessed boxes.

Depending on your method of mounting the legs, you may not want the shoulder holes cut out in this layer.

LAYER 2 (OUTER LAYER)

This is the outer layer that gives R2 his look. This layer should look like the picture I have attached. The solid black areas in the picture is what your layer should be left with. This layer should be glued on to the first layer. Line it up in the middle of R2's body. using the DATA SLOT and the CONTROL ARM holes to make the alignment perfect. WARNING: Be very careful handling this layer once it is cut out. It will be very flimsy due to the thin areas of material that remain.

LAYER 3 & 4 (Details and Doors)

This is not another layer, it is just the left over pieces. Layer 4 shows the backing skins for the doors. The "window frame" pieces glue on the backing skins shown in layer 4. This is what gives the doors the proper recessed look. The small solid panels just glue in the appropriate cutout on to layer 1.