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Gonk Droid Build
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Navajo Bro ()
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PostPosted: Thu Apr 26, 2018 2:00 am    Post subject: Gonk Droid Build Reply with quote

Dave and I are going to build a Gonk Droid so we have another cool prop for display at events Smile

We're going to do it in a way that also allows for the donation at applicable events to go right into the droid itself. There aren't a ton of tutorial out there so we're going to try and document one here.

To get started we had two perfect looking bins, but once we began mapping it out we found two minor flaws - it was relatively big (leading to sturdiness issues) and the handles were very obvious. Some browsing at Home Depot found two other bins just about as big but with less of a handle so we opted for them.

We're going to use 3" pvc pipes for legs, 1 1/2" pvc pipes (and wood) for inner stabilithy and a ton of random found and purchased parts for surface greeblies. Here is a part list (which will be updated as we go)

(2) 27 gallon Bins from Home Depot for body
(2) small storage bins (13 1/2" x 8 1/4") from Home Depot for feet
3" pvc pipe (probably like 6') for legs
1 1/2" pvc pipe for inner stability
4" dryer vent (silver) for over leg supports
(2) 3" to 1 1/2" reducers for leg to inner support connection
(1) drain pipe cover for donation slot
various metal plates from Home Depot
Wall phone port plate
1 1/2" tee connectors
left over FOTK belt rubber
left over Shore Trooper rubber shoulder strap
left over TK belt buttons / TD ab plate buttons
left over Inferno Squad helmet greeblies
chair/couch leg rubber stops
part of a disassembled Nerf gun
switch plates
small round wooden knobs from craft store
left over wood circles from base cut out
wood dowels
spare ABS plastic sheets
1/2" tubing
3/4" hose
9 1/2" x 9 1/2" tray from Dollar Store
sand, in a plastic bag wrapped in duct tape lol (homemade sandbag)
expanding foam
aluminum (or steel) flat bar
left over shelving (wood)
wax paper and painters tape
wooden stake
small rubber spacers from peg boards
fender washers
screw, nuts, wingnuts (I'm using size #8, various lengths)


(ongoing list)


501st link to soundbites:

https://www.501st.com/forum/viewtopic.php?t=28538


Album:
http://s199.photobucket.com/user/bro117/library/Armor%20Parties/Gonk%20Build?sort=3&page=1

Photos:



























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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout


Last edited by Navajo Bro () on Mon May 28, 2018 2:02 am; edited 2 times in total
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Stormtrooperbane (Alice)
Devaron Base XO
Devaron Base XO


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PostPosted: Sat May 05, 2018 2:13 am    Post subject: Reply with quote

I once wanted to be a gonk droid lol, in all fairness, I'm really short lol, this is awesome though, I don't see a lot of this droid
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Luckyjack (Jack Reuter)
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PostPosted: Sat May 05, 2018 11:08 am    Post subject: Reply with quote

I'm real excited to see how this goes Bro - as Alice mentioned, you never see one !
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Jack Reuter (aka LuckyJack)

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Navajo Bro ()
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PostPosted: Sat May 05, 2018 7:08 pm    Post subject: Reply with quote

ECCC and this weekend's events had me tied up the last few weeks, but now that they are done I plan to get going on this. I'll post up progress as we go Smile
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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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Joined: 28 Jun 2007
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Location: Neptune, NJ
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PostPosted: Mon May 28, 2018 2:19 am    Post subject: Reply with quote

Started with the feet. Cut the hole for the pipe, then put in the dryer vent. I cut one standard vent in half (be careful, after it's cut it's sharp since it's aluminum).





I made my own sandbags by simply putting some sand in plastic bags then duct taping them to the size I wanted. I want them to be in the toe area. To do this you wrap it slowly and carefully so you don't change the shape.


















I cut the legs into 2' parts using a miter saw. this way it sticks up into the bottom bin.






I cut a hole into the bottom bin for the legs








I used a drill bit to make a slot for the metal flat bars I'm using at the base support skeleton. Drill them in a row and then move the bit up or down to create the effect I need
















I then used some extra shelves Dave donated as the support






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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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Joined: 28 Jun 2007
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Location: Neptune, NJ
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PostPosted: Mon May 28, 2018 2:37 am    Post subject: Reply with quote

We're going to make it so this comes apart relatively easy. The base support will be screwed into the bottom part of the droid, however that too can come off if needed. This will make it easier for storage and transport.














We're making some supports to put a collection tray or power pack on.






For the front, I drew out a hole using the tray. I cut it with a razor and scissors, very carefully though so as not to split or crack it (which is easy to do with this type of bin)
















I'm using a few different droids as reference for the greeblies, along with some of my own








I was able to put together a pretty good likeness with the stuff I have listed in the first post






For the back, we're making it so it holds a pamphlet. We used some metal bars from the hardware store, wood and rubber spacers to fabricate this. It also sort of matches the toy reference I'm using which has three flat bars on the back










We're using the left over circles from the support cut as the right side details, along with the hose from an old non-accurate X-Wing Pilot chest box lol




We also made an ABS support base for each of the details on this side






Dave put in holes for the wood dowels that will help hold the hose






The other detail is the standard "E", which we also made from spare ABS plastic




The left side will have to switch and switch plate type details. They'll be screwed right into the bin after the details are dremeled off and they're painted










Dremeled off the lettering Smile





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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout


Last edited by Navajo Bro () on Fri Jun 01, 2018 2:22 am; edited 1 time in total
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Navajo Bro ()
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Joined: 28 Jun 2007
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Location: Neptune, NJ
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PostPosted: Mon May 28, 2018 2:50 am    Post subject: Reply with quote

Back to the feet.

I poked small holes into the back and top by they support let. I used expanding foam to fill the void. This way, the sandbag is the weight and the foam fills all the gaps so the leg doesn't wobble - but at the same time I can take the leg in and out (with the hole being maintained). We'll see how this works out Smile

I used wax paper around the leg so the foam won't stick














After a few hours the stuff that oozed outside was dry so I just picked it off. I took the leg out, and it worked, however the inside was still a little wet and began to ooze into the hole so I put the leg back. I'll leave it overnight and wait for it to completely cure










For the top/bottom I want to be able to take it apart if needed (especially if we are using it for donations so we can collect the money). We are using the wood stake cut into blocks and screws / wingnuts for this. We put some E-6000 around the wood block to give it some security, even though the screws are what's holding it in place.












We're adding the drain on the top to act as a collection slot, so we cut out the center to make the slot a little larger. Dave got black hand from doing that hahaha, it's worse then cutting resin Smile






We glued on an ABS base which we'll then cut through for the drain attachment




Greeblies are all set to go, next up is painting!!!!
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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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PostPosted: Fri Jun 01, 2018 2:30 am    Post subject: Reply with quote

Quick update as I got a few things done since the armor party



The foam in the feet seemed to work, I left it alone for a few days and it finally hardened up and kept it's shape.  






Glue dried on the donation slot plate so I cut the hole.  After painting I'll glue it in place:










I sanded and washed everything, then let it dry for a day.






I painted the side panels two different colors to see which I liked best - I'm going with the lighter one.  I painted the circle details in the darker and am doing some of the other greeblies in the same dark brown.  Some stuff is grey, the front tray is black.











Ralph brought over a ton of really cool aircraft electronic parts, so I spent a bit testing layouts and came out with one I liked.  This one circle piece also has burned out dangling wires which I can pull out for Jawa photos hahaha












I cut out holes and slots for most of them, so they can be secured better.  I'll also glue or affix from the inside after initial painting





























The new tray layout



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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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PostPosted: Sun Jun 03, 2018 11:12 pm    Post subject: Reply with quote

Got a lot done the last two days Smile

Pretty much painted everything, I'm going to go back and weather a little more with Dave and an airbrush but here was how it came out.




I got some "stone" spray paint stuff with does a fantastic and super easy sand weathering Wink I spray it on then a quick dusting of the normal brown I'm using to make it blend in a little more then it would









Dave popped by the other night for a few minutes (he's literally a mile away) and helped me attach a few of the side greeblies. for the center plug it just pops through, the other stuff was a mix of screws and cutting out slots. some stuff had a little tape for extra support, others used velcro and one we made a little abs cross beam and tied twine through the little slots to keep it in place. I'm trying to use as few real world screws as possible but also use a little more then just glue




















Outside is straight up E-6000 Smile










And for the donation slot just straight E-6000 around the edge


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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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Joined: 28 Jun 2007
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PostPosted: Sun Jun 03, 2018 11:20 pm    Post subject: Reply with quote

Everything came out very nice, so at this point I put it all together (after painting the feet grey)

For the tray, after the details were on I literally (and carefully) just pushed it through the opening. It's tight enough I don't need any glue or other means to secure it



































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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Navajo Bro ()
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Joined: 28 Jun 2007
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PostPosted: Sun Jun 03, 2018 11:24 pm    Post subject: Reply with quote

And that's a wrap!

Dave and I are going to do some airbrush weathering, and I'm tossing around some ideas for adding "toes" (made out of foam and latex), tubes from the feet to the base and some knobs over the circle parts on the side, but basically he's all together and ready to troop!!!

Smile









(for size comparrison)


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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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carlamariegiac (Carla)
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PostPosted: Mon Jun 04, 2018 12:48 am    Post subject: Reply with quote

Ohh man I could TOTALLY fit into that and make it walk LOL. Razz
It looks awesome, great work! Can't wait to see it at an event.
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Carla Giacalone | Devaron Base, BPR | RLGS - Delegation of Assarda DL; UCGR; Wretched Hive, Twin Horn Clan; KJO, Temple of Eedit; DB 94, Hangar Bay I-95
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Navajo Bro ()
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PostPosted: Mon Jun 04, 2018 1:31 am    Post subject: Reply with quote

carlamariegiac wrote:
Ohh man I could TOTALLY fit into that and make it walk LOL. Razz
It looks awesome, great work! Can't wait to see it at an event.


It was honestly so easy I am thinking of making another one that people can get into hahaha!

The only thing I need to find is "leg sleeves" and something for shoes. The aluminum is too sharp and the bins are too fragile. Once I source that out I'll make a "costume" one for whoever wants to get in it Wink
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Nahon-Ish Maee
Quinlan Vos/CW Obi-Wan/Han Solo/X-Wing Pilot/ARC Trooper Blitz
Devaron Base

TA/TB/TI/TK/TK/TS/TS/TX/AR/BH/IC/ID/IS-8869
501st Legion
Northeast Remnant Lead Event Coordinator

501st Legion Trooper of the Month - July 2012
Special Ops Squad Leader - October 2012
First Ever 501st Legion approved Snow Scout
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Luckyjack (Jack Reuter)
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PostPosted: Mon Jun 04, 2018 2:41 pm    Post subject: Reply with quote

That came out awesome Bro !!!!!! Shocked

Can't wait to see it in "action" on a troop !
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Jack Reuter (aka LuckyJack)

Tusken Raid

Tusken Bantha Rider
Old Republic Jedi Knight
Qui-Gon Jinn
Devaron Base

TK / TB / DZ 4997
501st Legion
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Mando Mercs - "Lucky" Jak Tang
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TanRu ()
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PostPosted: Tue Jun 05, 2018 12:27 pm    Post subject: Reply with quote

Navajo Bro wrote:
carlamariegiac wrote:
Ohh man I could TOTALLY fit into that and make it walk LOL. Razz
It looks awesome, great work! Can't wait to see it at an event.


It was honestly so easy I am thinking of making another one that people can get into hahaha!

The only thing I need to find is "leg sleeves" and something for shoes. The aluminum is too sharp and the bins are too fragile. Once I source that out I'll make a "costume" one for whoever wants to get in it Wink


Oh man, this would be great!

How about dryer vent duct for the legs?
https://www.homedepot.com/p/Everbilt-4-in-x-8-ft-Dryer-Vent-Duct-BTD48HD/203626496

The main thing I'd worry about is the weight - I don't think you could troop with the weight of 2 bins that size on you. Maybe a PVC frame and some suspenders, with plastic sheeting as the shell?
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