2009 Holiday Air Affair

The 2009 Holiday Air Affair was another success. As an R2 Builder, I took on a lesser role this year opting to spend more time with the kids. Santa arrived on an Ashland Fire Truck and was escorted in by Stormtroopers.

Hannah and Joshua got to sit with Santa and tell him what they wanted for Christmas. Wouldn’t you know it, a huge building full of airplanes and the kids decide to play with blocks.

The R2 Builders gathered before everyone got there for pictures.

The crowds and the picture line formed. Everyone loves Star Wars, and Brad and Syrena (Darth Vader and Princess Leia) decided to ham it up.

I saved the best picture for last. One of the 501st members let some kid dress up in his Jawa costume. The R2 Builders got him to hold Brad’s R2 dome above his head (Brad suffered only a mild heart attack).

Star Wars In Concert Hits Omaha

Star Wars In Concert finally made it to Omaha and when it arrived it brought a blizzard with it. I was hoping the concert would be rescheduled, but no such luck. I was surprised to see how many people braved the storm. I guess when the Qwest Center tells you they won't reschedule or refund your money you find a way to get there (getting home proved to be a little more difficult, but that is a story for another time). The Rebel Legion, 501st, and the R2 Builders were at the concert; but unfortunately, they left their droids at home. I loved seeing all the Star Wars costumes and props.

The man that helped bring down the Republic!!!

I finally got my picture taken next to a back drop. There were LARGE crowds of people in line for every display area.

A senate guard and the Emperor's Guard! I use to have one of these as a kid. I told Michelle this and she looked at me like I had two heads.

C-3PO, the man...the droid...the Star Wars In Concert host.

Builders show off their new costumes!

Han Solo in Carbonite!

Center Leg Support

I needed a change of pace tonight so I decided to work on the center leg supports. I cut a piece of 3/4" plastic down to 5 1/2" x 12" to use as the sliding plate and then dry fit it to make sure I had enough room for it to move between the side supports of the frame.

I then cut to two 5 1/2" boards to sandwich the plastic and act as top and bottom anchors for the four sliding rods.

Moose and I then lined up the sides of all the boards and clamped them so we could drill holes through all three boards. That way they would all match and we wouldn't have to worry about the center plate binding when the center foot raises and lowers.

The top plate will be slightly below the center outer leg pipe and the bottom plate will rest base of the frame. We temporarily screwed the bottom board into the frame base plate (I will replace it later with bolts) and dry fit the remaining boards. The hole size is perfect for the top and bottom plates, but I will have to make the holes in the plastic plate a little larger to allow it to slide easier. As with framing a door, the center of the bottom board will be cut out once the sides are permanently attached.

The four rods were not cut and the top board was not permanently attached because I want to get the skirt installed and the center leg assembled to determine the exact location everything needs to be.

Pumpkin Carving

We decided to take a break this week from R2 Building and do a little pumpkin carving and watch some Halloween movies. I carved a Darth Vader in a real pumpkin and started carving an R2-D2 in an artificial pumpkin.

Cutting Dome Panels

After my leg work was done, I did a little dome work. I number all the panels and started cutting them out. The smallest arc on the dome panels where too small to use a Dremel so I left the bottom corners of each of the panels uncut with the intention of cutting them after I cut the top arcs. I used a carpet knife (I left my exacto knife at home) to make a deep score in the top arc, finished cutting the bottom panel corners, and then slowing bent the panels inward causing them to snap/break on the score lines.

Sanding/Chisel Work On Outer Legs

I borrowed a large sander from my father and the group sanded their outer legs. Thanks Pop, the group really appreciated it! I got a little aggressive in some areas, so I will have to use bondo here and there. The legs turned out great.

Steve and Jeff worked on assembling Steve's outer legs with all the new hardware he picked up.

Moose, Brad, Syrena, and Steve cut some pipe and angle iron for their 3-legged R2s. And Brad even did a little welding for Syrena.

Moose, Brad, and Syrena worked on cutting the pipe holes for Syrena's droid.

I used a chisel and file to cut out under R2s shoulders and square off his ankles.