Counterweight's Second ROTJ Cardboard Scratch Build

[Silverstalker]

Gauntlets ay I had a felling this would really bite you in the but to do the whole thing

 

[Counterweight]

Gauntlets ay I had a felling this would really bite you in the but to do the whole thing

Well if I'm being honest it's pretty much your fault with your ROTJ SE build lol

 

[Counterweight]

Hey guys,

I recently began working on my gauntlets for the first time. If anybody is interested, that thread is here:
http://www.thedentedhelmet.com/f20/counterweights-rotj-build-55560/

As far as the helmet goes, I'll be getting the visor and necessary electronics relatively soon hopefully. That will help with the gauntlets too because I want to put the RC servo controller in the right gauntlet, so I can't assemble the gauntlet until all that is in there.

Again, thanks everyone! I'll update this thread once everything is finished

 

[Counterweight]

So I bought/scavenged a few things and have been watching video after video and I think I'm ready for the electronics

I don't have everything that I need but I have enough to start. I have that small fan circuit that I'm going to add a switch to so I don't have to remove the battery every time. I also have a solder kit for the red LEDs.

I have a white LED that I took from something else I had, but I'm not sure how to do the circuit. I was hoping to power it with the same battery pack as the flashing red LEDs, but I'm worried that it too will flash since its on the same circuit. If anyone knows how to do that PLEASE let me know.

I still don't have a servo or a servo control RC chip for the gauntlet, so that project still has to wait

So that's it for now. I'll post pics when I'm done soldering everything together.

Anyone with any electrical knowledge feel free to lay some tips on me. I know very little about all this lol

 

[Silverstalker]

Ah so you found the metronome kit take your time putting that together its so damn small. and yes if you put the white LED in line with that circuit it will flash, LED's are also very fussy about their voltage, to low and nothing happens, to high and they pop.. so it may not run the 3rd light anyway or may end up with a dim flashing red LED.

What I would suggest you get is some shrink wrap for the LED ends of the wires, what I found with mine is the space got a little tight up in the range finder and there was always a risk of the ends touching...electrical tape is messy and bulky...

other than that you are well on your way

 

[Counterweight]

Ah so you found the metronome kit take your time putting that together its so damn small. and yes if you put the white LED in line with that circuit it will flash, LED's are also very fussy about their voltage, to low and nothing happens, to high and they pop.. so it may not run the 3rd light anyway or may end up with a dim flashing red LED.

What I would suggest you get is some shrink wrap for the LED ends of the wires, what I found with mine is the space got a little tight up in the range finder and there was always a risk of the ends touching...electrical tape is messy and bulky...

other than that you are well on your way

Yeah the shopping list was very helpful thanks!

 

[Counterweight]

So time for a progress update on the electronics!

I was able to completely wire and install all of the rangefinder LEDs (yes including the white). For the red two I used the Velleman mk 102 flashing LED solder kit, and for the white LED I just spliced in a basic circuit with an LED and a 300 ohm resistor JUST before the flashing LED circuit. So both share the same power source, and it works great!

I also did a basic circuit for the fan and included a slide switch.

I'm waiting on installing the micro switch and soldering the lights to the power source until I can get the servo installed, because at the moment, the stalk is not attached to the helmet. So I don't want to permanently affix those things until the stalk is installed on the servo.

Speaking of servos, I need HELP. I am thinking of getting a 9g micro servo, but I have no idea what else to buy! I believe I need some sort of controller board and receiver board, but I have no idea where to look! Internet research hasn't yielded much so far, so please if anyone knows what/ where to get aside from the actual servo itself, I would really appreciate it. Until I get it, I'm stuck.

Also I need to buy the visor, Perspex block, and Borden connector as well!

I still have plenty of work to do but the finish line is in sight! So excited

Here are some pics of the progress. Hopefully the video works as well


The mk 102 kit

The fan circuit

The red LED circuit board with the white LED installed in the rangefinder

The fan circuit installed in the helmet. It may have to be moved to accommodate other components later though. We will see

The progress so far

So that's it for now. Once I figure out the servo issue, I'll be able to put everything else in. Haven't decided on whether or not to do an audio rig yet.

 

[Level3Fett]

Very nice dude.

 

[Counterweight]

Very nice dude.

Thanks bro

 

[Silverstalker]

Turnigy Servo Tester

I used this, took its guts out and fit it to my gauntlet, but pu a switch inline with it so its not on all the time.

 

[Counterweight]

Turnigy Servo Tester

I used this, took its guts out and fit it to my gauntlet, but pu a switch inline with it so its not on all the time.

You sir are a genius

This is probably a stupid question, but I know nothing about servo testers. Would I be able to control it remotely from the gauntlet or will I need to run a wire all the way up my arm to the helmet?

 

[Silverstalker]

you will need to extend it, up the arm through the neck seal and connect into the helmet. its tricky getting it all on but once connected just stuff the wires down your seal... a spotter will help. or passer by

I did find that the servo testor worked best with an analogue servo, it didnt like the digital one for some reason...

 

[Counterweight]

you will need to extend it, up the arm through the neck seal and connect into the helmet. its tricky getting it all on but once connected just stuff the wires down your seal... a spotter will help. or passer by

I did find that the servo testor worked best with an analogue servo, it didnt like the digital one for some reason...

Aw that's too bad. I was hoping for RC lol
As always I'm stuck between getting what I'd prefer and getting something cost-efficient. I'll probably do the servo tester. It's a rather elegant solution! Thanks again for all the help on the electronics

 

[Counterweight]

Brief update since its been awhile. Not a lot has been done unfortunately. Mostly money issues :/
This stuff adds up fast!

Anyway, I made an executive decision and decided to go RC! That's just an aspect I really wants to incorporate and so I decided to bite the bullet and try it.

As of now I don't have everything I need so the progress will still be slow.

I recently bought a RadioShack Zip Zap mini RC (attempting to follow the sticky thread)

I took that bad boy apart and now I am the proud owner of a transmitter circuit board

and a receiver board

So this is all I have for now

I still need the servo (I'm planning on the low profile servo, but wondering if maybe I can get away with a 9g micro servo), two battery boxes, the gauntlet switches, the t-visor, the Borden connector, and the Perspex block and I'll be done with the helmet finally

This will also go in the full costume thread when I'm done with them, but for the record I began the bondo process on the gaunts so that I can have them finished (or close to it) for when the electronics are done.

Very close to a working RF! Wish me luck

 

[Stlfett]

Fantastic work!

 

[Magikarp]

Any tips in making the dome?

 

[Counterweight]

Any tips in making the dome?

Don't do it like me lol jk

Biggest thing I found was to lightly mist the dome slices and curve them. Let them dry overnight so they're easy to shape. Other thing is to build the dome bondo in multiple layers. Do a light layer, let it cure, sand it, then start on the next layer.
This helmet took 5-6 thin layers of bondo

Hope that helps!

 

[Magikarp]

Thanks! And i like what you have done so far. Your helmet looks great

 

[Counterweight]

I'm updating this thread and my costume thread at the same time because I'm doing my helmet and gaunts at the same time, so for a more detailed look at the gauntlets you can check out my costume thread.

pic heavy post


So I got the 9g micro servo and took it apart so I could splice straight to the motor

Got everything wired up

...and fried the receiver. Probably because I was using the micro servo

So I bought a new zip zaps and a low profile hitec hs77bb.

Same thing: opened it and cut the wires in order to wire directly to the motor

New receiver board

Apparently my earpiece got in a fight with a dremel and lost...
Yes I'm aware it's super ugly but it's functional and it will be hidden by the earcap

I found a little metal piece that fits perfectly in the ear and stalk, so I'm going to use that and screw it to the servo

Okay so the screws aren't long enough so looks like I'm going with JB weld...

Here's the transmitter in the right gauntlet

Got my t-visor in!

Lookin fresh

Now it's time to install the rangefinder and micro switch circuit. I'm going to solder the pos. lead from both the power source and RF to the micro switch posts

With the RF JB welded to the servo attachment

I'll reiterate: ugly... but functional

And final connectivity test. You can see the light in the RF housing in when I push the micro switch

Okay... the big moment is here, the JB weld has cured for about 10 hours and should be strong enough to test the whole system. The RF top is pretty top heavy, so I'm a little worried. We will see how it goes!

Damn it... so close

So the torque from trying to lift the RF back up broke the job weld. I'm going to reattach it and let it cure for a full 24 to make sure it's solid. If it doesn't work again I'll have to think of a stronger attachment method.

Also, you can see that it's not working unless the gauntlet is very close to the helmet. I don't fully understand why... but it's something I can look into later. If anyone knows anything about please help me out!

So here's my current setup inside the helmet (don't judge it... it's super amateur)

From left to right: servo (top), RF power source (bottom), receiver board (top), servo power source (bottom), cooling fan

I want to eventually get another fan, audio pick up, and mic system in, which will adorn the left side of the helmet.

So that's where I stand as of now. Just waiting on my Borden connector from some dental website and JC Perspex block from shapeways. Also have to get some padding for the inside (any suggestions?) and the helmet will be tentatively finished.

Still working on the gauntlets. Both are painted and almost done. Go check out my full outfit thread if interested in that.

As always, criticism or suggestions welcome

Thanks

(Sorry for the super long update!)

 

[Magikarp]

The gauntlet needs to be close because the transmitter doesn't seem to have a long range. But I'm no technical genius myself so i can be wrong (i am only 15). Or that the helmet itself is blocking the signal. Still I'm just thinking out loud.