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Thread: Cl4P-TP Build

  1. #1

    Cl4P-TP Build

    So I've been sorta hiding under a rock for awhile..... But many of you here know me and have followed a few of my older mods so I HAD to share this one!

    I've been working hard and not posting to complete it for the deadline for a case mod contest. So it's "Finished".
    The good news for you is you'll get updates start to finish quicker then if I were still working on it. Bad news it will still take me a few days or weeks to get everything up here. There are also somethings I want to Fix/ Change already.
    So as I upgrade this Mod I'll add new posts.




    Claptrap Is sporting a GIGABYTE GA-MA69GM-S2H AM2 Motherboard with an AMD Phenom X4 9850 Quad Core CPU. The CPU is Cooled by a Corsair H50 water cooler. Graphics are handled by a SAPPHIRE 100251SR Radeon HD 4870 X2 2GB. 8Gb of Corsair XMS2 ram help out. A Maxtor 500Gb and a Seagate 1Tb Hard drives Round out the Storage. All of this is powered by a CoolerMaster 750W PSU.

    IF you head over to LanOC.Org 's Summer Case Mod Contest
    You can see more Cool Mods, Vote on the winner and see some "finished" pic of my Mod now... no waiting for me to post them.

    Enjoy,
    CBB

  2. #2

    Cl4P-TP Build

    The First step was to gather many, many, many screen caps of the different ClapTraps in Borderlands. From them I was able to create a model in CAD so that I could cut out all the pieces at the same scale.


    The outside of the case is made of 1/4" Plywood.



    A rough outline of the parts were cut from a large sheet, thus making them more manageable and it easier to cut accurately.


    1 by 2's reinforce the corners and side cutouts to distribute the weight and strengthen the case. All the joints are glued for strength, and then nailed together with brads just to hold till the glue sets.



    Once the outer shape has dried, the front cutouts are made using a Jig saw. It's a bit more difficult to cut on a compound angle but it helps make sure that the details are centered.




    This is where I'll leave it for now.... More later!


    When I first started to design the case I was going to mount the Motherboard directly to the back wall of the case. As I went into the build phase of the case I realized this would limit many of my component choices due to size and the wheel in the middle of every thing. So I revisited the "Mounting Plate" that I used for my Pak N Play mod.
    It's basically a 1/8"+ thick plate of Aluminum (6061) With tapped holes for Stand offs and a custom HDD and PSU mount.


    I wanted to increase the amount of storage I had, so the Drive rack was expanded to hold Two standard HDD One on top of another. The Second Drive is a 1Tb Seagate This gives me 1.5Tb internal on Cl4p-TP.


    With the Change to the Plate I had to add a plate mount to the case. This was accomplished with a piece of 1"x6" Pine running across the case about 1/4 of the way down (half way down the stripe) This also had the added bonus of giving me a solid place to mount the wheel strut to later!


    Just for Fun I stuck the wheel in there to get a feel for the size of the case (the wheel is 10" in Dia and 3.25" across)


    Some of the details are key points that help align other features so I wanted to get them in early... So I started with the main Eye and the bit of detail below it.


    Before I could start on the Lid I needed to level the ledge around the top out (this is one of those little mistakes. I didn't think about the sides being angles so I glued the top supports in @ 90 degrees that would make designing the top which has like 3 different faces on it even harder to make...) So I cut out a rectangle that fit inside the case then cut the center out a little glue and some brads and we have a flat surface to work from!


    Ok, at this point I was a bad Modder, I forgot the camera on 2 of the days we worked on this project.... The Day we made the wheel mount, and the day we cut the side rails for the top Those were important days so I've got some leftovers from the lid, and can piece together some of the Wheel mount stuff so I'm going to do my best to "recreate" the missing days, it will just take me some time because, it was all done at my buddy's shop, and I'll not be back there for a few days... but I will fill you in!

    CBB

  3. #3

    Cl4P-TP Build

    So One of the Next things I did was to Create Claptrap's Unicycle style wheel.
    It's load bearing so it has to be strong, but easy to bend..... Black Steel Gas/Water Pipe that's the ticket!

    BIG PIC

    Balancing on one wheel would be tough to pull off. So I came up with a novel Stealthish Kick-Stand.

    BIG PIC


    I'm still missing pics of the Bending of both parts...but moving on.

    I welded a plate across the top to give plenty of surface to spread out the load and bolt to the wooden cross brace. Then a couple of coats of 1200degree Ceramic Flat black paint (it's what I had on hand that day).


    Big pic

    Next step on to the Lid.

    You would think that The Lid would be the Easy part right...A large flat Rectangle.

    Your in correct. I made the lid like you make cabinet doors. The outer edges are solid wood and the center of the part is plywood. Why did I do it this way. Because the Edge of the lid has a crazy profile. It has an outer lip so the lid can sit down on the base, an inner lip for the plywood (this allows the whole top to be flat), and the out 1/3 of the rail is cut on an angle. Toss in the angle cuts for nice corners and you have lots of angles to work with.

    Here's a look at the profile (cross section) of the lid rail.

    BIG PIC

    To cut down on the fasteners you can see (and angle holes to drill (screw up)) I used Biscuits to join the corners.

    BIG PIC

    A Biscuit is just a little football shaped piece of plywood, that is designed to fit into a slot you cut into adjoining pieces of wood. The plywood will swell a little when you cover it in glue between the glue and swelling you get a nice tight bond and it's hidden inside the wood.
    Here's the Lid Rails and styles glued together.

    BIG PIC

    The piece of plywood was cut to fit snugly into the lid frame's lip.
    I used Gorilla Glue to join the two parts... and lots of weights to hold everything while it dried.

    BIG PIC


    A little wood putty and sanding smooths everything out.

    BIG PIC

    What to post next??

  4. #4

    Cl4P-TP Build

    With the Top done it's time to work on the bump that will house the water cooler radiator. The hump is a plywood top and solid sides. The vent details will be cut out to allow air flow. First step cut the vents.

    BIG PIC

    Part of the way complete.

    Fully cut.
    BIG PIC

    The Vent edging is made out of solid strips of pine.
    BIG PIC

    The solid pieces are cut down for sides, tops and bottoms.

    BIG PIC

    Once glued up this is what the edges look like.
    BIG PIC

    With the Lid complete The Next step was to get the Arms in place.

    The arms are PVC water pipe. The upper arm is 1 3/4" the lower arm is 3/4". The Elbow and Wrist joints are 1/2" and 3/8" socket universals.

    BIG PIC

    I welded some washers on the ends of 3/8" steel Rod. The other end of the rod was beveled with a grinder and cross drilled for a cotter pin. These Rods go through the 3/4" wood vertical, trough matching holes in the PVC Pipes, and back through the second vertical. This allows the arms to move up and down. A couple of washer and the cotter pin keep the rods from working their way out.

    BIG PIC

    While I was welding the Rods I also fabricated the hands. I wanted Cl4P-TP to be able to grip things. So I start with a steel spring clamp, an old 3/8" drive Socket (I think it was a 10 or 12mm one). The socket was welded to the back of the Clamp. this allows the hand to be disconnected and repositioned on the end of the arm in more ways than could be done with just the universal alone.

    BIG PIC

    Once the Socket was welded on The Shields were welded in place. The shields are to give Cl4p-TP's hands the correct look from the game.

    BIG PIC

    Both hands fully welded.

    BIG PIC


    CL4P-TP also has Some Sheet metal Shoulder pads and a Steel Eye bill.

    I cut the Base parts of these out of 16 gauge Sheet steel and the details were made from 20 Gauge sheet steel.
    My Trusty Cordless Jigsaw made short work of the 16 Gauge steel. Tinsnips were needed for the 20 Gauge steel.

    BIG PIC

    All these parts have a dimpled cover. To make the covers I laid out a staggered grid pattern on the back of the part. On every intersecting line I made a dent with a custom ground cold chisel and a ball-pion hammer.

    BIG PIC

    Once complete the part was flipped over and you can see how nice and smooth the dimples are.
    BIG PIC

    The Shoulder pads are made of two parts the larger base and the smaller dimpled detail. They run around the edge of the lid so there is an angled bend that needs to be made so they sit flush, both the base and detail have to match on another and the lid.
    To do this we used a bending break.

    BIG PIC

    Here is a look at the Eye Bill all the pieces are setting together before they get welded fast.

    BIG PIC


    I had to come up with a way to attach the metal parts to the wooden lid. My solution was to weld bolts to the base pieces and use washers and nuts to hold them tight. To do this I cut the heads off some long machine screws. Then I drilled holes the same size as the bolts into the base plates. The bolts were welded from the top, and ground down flush.
    Here's how the looked from the bottom.

    BIG PIC

    The Details were then welded to cover the holes in the base.

    BIG PIC

    So I've been welding allot on this Project. What am I using? It's a little 110V Lincoln Electric MIG.

    BIG PIC



    Next Time I'll cover some of the Front Details, and Radiator mount, which will leave base Painting to be covered in a later installment... That will get you caught up to present.


    CBB

  5. #5
    The Main Man Dewayne's Avatar
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    Cl4P-TP Build

    So I've been sorta hiding under a rock for awhile.....
    I would say so! Glad to see you back in action!

  6. #6

    Cl4P-TP Build

    I've Moved 3 times, Been Laid-off and going through the BIG D *.....

    Things are finally stabilizing somewhat... so I've gotta Mod something





    CBB















    * and I don't mean Dallas!!! 8O

  7. #7

    Cl4P-TP Build

    To Mount the Radiator In the Lid hump I needed some Straps. So I settled on some simple T Straps made from Angle aluminum and some flat Aluminum. In typical Hillbilly Fashion... I left the camera in the car for the cutting and welding only pulled it out when things were cooling...oops
    BIG PIC

    Once the Rad was bolted to the angles The Flats were marked, cut to size and screwed down.

    BIG PIC

    The Front Eye Detail is made from a cereal bowl found at a dollar store. I cut part of it off on the band saw so it would fit correctly, Then Painted it with Black Fusion for plastics.
    BIG PIC

    The bowl needed an extension so a 2" PVC pipe Coupler joined perfectly to extend the Eye. A bit of Zap a gap to hold it all together.
    BIG PIC



    To bring everything together A little color. All the Gray and Black Parts are masked off and a base of white primer (2-3 coats), two coats of white paint, followed up with 3 coats of Clap Trap Yellow.
    BIG PIC


    Next time I'll cover the rest of the paint and The Final Pics!!!


    CBB

  8. #8

    Cl4P-TP Build

    Paint!!!



    The painting Process started with 4-5 coats of Gray Primer that were sanded back and 2-3 more coats were added. Then I attempted to spray the yellow over the gray.... Two coats in Cl4P-TP was a blotchy nasty greenish color. So I hit it with 3-4 coats of white primer. Sanded it back, and covered it with 2-3 coats of flat white paint. Then the Whole thing was painted with 3-4 Coats of Yellow.
    After the yellow dried (2 days) I masked off everything but the gray areas on the top and back. This area was given 3 coats of Gray primer.
    BIG PIC

    BIG PIC

    Once the primer dried it was masked off too, and I started with the White stripe. I masked of random spots of random shapes and Sizes. This is to give you the illusion of places the stripe paint has worn through and the base coat is showing. This masking was done with torn blue painters tape.

    BIG PIC

    BIG PIC

    Here's a shot of the hinged metal plates that hang down and cover the arm to body joint.

    BIG PIC


    So do you want to see the "Final" Pics ???




    CBB



    Or comment about the work-log here and maybe I'll Post them quicker....

  9. #9

    Cl4P-TP Build

    Once all the Paint Dried and the Mask was torn off. THis is what appeared. (Ok so I did paint a few details like cdrom door with a brush before these pics but...)

    The Motherboard and cooling system is in place in this photo.
    BIG PIC

    Here it is Hooked up and turned On.
    BIG PIC

    and some shots from the sides
    BIG PIC
    BIG PIC

    A quick shot of his bum
    BIG PIC

    Face Time!
    BIG PIC


    This is the point I called the mod "Final" for the LANOC.Org case mod contest. But it's not what I wanted... It needs some Lights, some dirt, some patches, and an easier way to hook up the wiring.
    So What's a Modder to do? Well I Take my second place mod and keep mpdding it! Keep watching cause I have more updates coming!

    Thanks to everyone that voted in the contest! I couldn't have gotten second without you!!

    Till the next update!

    CBB

    Also Look For Cl4p-TP At the Nexus Lan in Dayton, Ohio October 23, 2010

  10. #10
    The Main Man Dewayne's Avatar
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    Cl4P-TP Build

    Great job man! I always find that a mod is never really complete. As you always have something in the back of your mind going... " Hmmm, now if would of done this I could have changed this and..."

    Hey take some pics at the LAN and post them up here as we all would like to see it in action as well as other mods.

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