View Full Version : ED 209 Scout

08-08-2008, 08:10 PM
Well after receiving my biped scout from Tom I have been busy trying to fit my ED 209 head to it, Here are some pics to date, Of course it will have to be painted, but had to install it and see how it looks, your feed back would be appreciated.


As arrived from Tom.


Putting it together.



ED 209 head.



Installed head on pan/tilt.


Front view, Looks mean.


Back view.


Foot pads may be incorporated, front and sides.


Low down look.


Now it does look really mean.


Side view.

Let me know what you all think, and if I am on the right tracks here.

08-08-2008, 08:15 PM
Looks awesome! Needs guns.

08-08-2008, 08:19 PM
metaform3d, I have not got that far yet, it's coming. I hope.Building this is not a problem, programming it will be.

08-08-2008, 08:20 PM
With those monster servos, he could probably mount a dotFifty on there. Careful what you ask for! :)

That looks sweet! Hinge the "jaw" and make the gun deploy from its "mouth" :)

08-08-2008, 08:24 PM
Ha Ha Adrenalynn, nice thought, Twin gattling guns would also be nice. Gun arms next on the list.

08-08-2008, 08:51 PM
metaform3d, I have not got that far yet, it's coming.No pressure. Looks really good!

08-08-2008, 09:11 PM
Dang that looks sweet. That is the kind of Mech I imagined.


08-08-2008, 09:45 PM
Sweet! that model top really adds a touch to the base. Your right Gattling guns a must! hehehehe

08-08-2008, 09:49 PM
You read my mind GW, But then again we know somthing other's don't. He He

08-08-2008, 09:59 PM
4mem, I never feel worthy to comment. But it looks super cool!
I like the "toes" too!

08-08-2008, 10:27 PM
The toes do looks very nice!

But wouldn't the head look cooler if was hallowed out and place over the yellow "body" of the scout? It seems to me that it would look a lot like ED 209. You could even turn the head when it's hallowed out!

Just a thought :rolleyes:

The crafting looks AMAZING. Did you do it with a CAD then CNC?

08-09-2008, 12:14 AM
Hi Sam, No this head was from a kit that is about the right size, I cannot lower it as I have a pan/tilt system under the head and, Also the body is NOT wide enough to hide the lynx top platform. When the gun arms are on it will look better.

08-09-2008, 04:27 AM
Had to go and do some more robotics during the forum chat today, so here are the efforts. Fitted the left arm on the Ed 209 ready for the Gattling guns.


Had to make two left and right custom alloy brackets to mount the shoulder servos.


Large flat area sits on top of the biped lexan front frame.


1 HSR 5990 and 1 HR 645 for the shoulder.


Left shoulder mounted.


Side shot of shoulder.


Close up.


Rear close up of left shoulder.

08-09-2008, 04:32 AM
Oh yeah, this will be ED-209 done right! I like it! :veryhappy:


08-09-2008, 04:39 AM
Thanks Dale, No problem building it, Programming it will be.

08-09-2008, 06:21 AM
Thanks Dale, No problem building it, Programming it will be.
I'd offer to help with the programming, but as you know, I am majorly occupied with W.A.L.T.E.R. at present.

I also have this new robot I am almost ready to start writing software for too. You can count on it being unique and probably not like anything seen before. At least I have not seen this done quite this way before.. :veryhappy::veryhappy: This robot is constructed almost entirely of stuff I had on my desk or workbench.

I'm taking assembly pictures along the way. I am just finishing up the locomotion system. Then I have to mount the sensors and finally start working on the software. It will be fully autonomous, at least as far as we are normally able to do autonomous.


08-09-2008, 06:25 AM
What methodology are you using for Localization, Dale?

08-09-2008, 06:29 AM
What methodology are you using for Localization, Dale?
I'll start a new thread as soon as I figure out a name for this new robot. :veryhappy:


08-09-2008, 07:21 AM
Sounds cool Dale, Look forward to seeing it.

08-09-2008, 07:30 AM
I love the arms!

Nice job, you can really see it coming together!

08-09-2008, 07:53 AM
Thanks Sam, Will do the right arm tomorrow if time permits.

08-09-2008, 03:13 PM
You read my mind GW, But then again we know somthing other's don't. He He

That we do my brother that we do. ;) Although that hinged mouth gun sounds really neat. I know you can pull that one off , Just thought of something instead of a gun, shoot out flames then launch a rocket. What a great view that would be!!

08-09-2008, 05:04 PM
GW, Nice idea, But I will be thank full just to get ED 209 walking at this stage, If you know what I mean. But I can't help myself to keep building accessories for this project. I'm getting the bug real bad.

08-09-2008, 08:43 PM
More updates on ED 209


Second Alloy bracket for left arm.


Both arms fitted and outstretched, You can either have the guns slung below or out higher up.


Arms lowered, Weapons low down.


Close up of left arm.


Close of arm lowered.


Rear view of Arms lowered.

Next I will be making molds for the larger front feet, These will be made of balsa and ply then prepared for mold making then cast in carbon fiber with some alloy inserted for strength.

08-09-2008, 09:26 PM
Looks relly nice with both arms on!

Are you going to paint the toes and the head?

08-09-2008, 10:34 PM
Sam: Yes I will paint the toes and head sections, What you see now is only being put together roughly to see if it all fits, Then it will get Painted. i have to make the molds for the feet yet and this will take some time, these will be molded in Carbon with some Alloy embedded in them, i will be spring loading them, So I have two front feet and four side sections all sprung loaded for Different terrain situations.

08-10-2008, 02:38 AM
Update Sunday afternoon.


Rear alloy bracket that supports the arm servos.


Custom Alloy bracket that supports the arms.


Servo arms attached to the custom bracket.


Bracket in place.


Rear shot of alloy bracket, Anchored to the SES frame for stability.


Side shot showing Rear of head removed and alloy mounting bracket.


Ha Ha, Guns mounted just to show what it MAY look like, Rockets to go on the side shoulder servo as when raised the rockets will be on top , also the guns will be higher up. These guns will be changed to Gattling guns.


Front shot of guns.


Clearer shot of weapon system.


Mean and dirty, ED 209 in it's crouching position, Extended it is half as high again. All in all a good weekends work.

08-10-2008, 04:05 AM
Holy crap, that looks nice!

And it's only Sunday technically for me -- although it's after midnight, I'm mostly still thinking of this as Saturday night.

08-10-2008, 04:10 AM
Thanks metaform3d, appreciated.

08-10-2008, 05:31 PM
Why don't you cut w hole in the bottom of the head, and mount the servos' inside the head?

Droid Works
08-10-2008, 07:15 PM
All I can say is WOW! That is awesome!

08-10-2008, 07:40 PM
Wow, your brackets are awesome! As always you set the mark very high for the rest of us!

08-10-2008, 08:40 PM
It looks amazing!

Won't you need another DOF on the wrists to level the guns as you raise them? Or will that be addressed when you relocate them since that was just a vanity shot?

08-11-2008, 01:44 AM
Thanks Adrenalynn, Appreciated. Ok Two servos, The first one [ inboard] looking from the front of the Mech, moves up and down, the other servo rotates from left to right, The idea being that rockets will be fitted to the outside of the second servo, When raised 90 degrees the rockets become on top of the shoulder and the gattling gun will be on the outside of the rockets, when in the upright position you can then move them up and down. This is just an experiment at present and may change to 3 servos, but I want to try this first as another two servos will make it 20 which is quit a few for this mech.

08-11-2008, 01:49 AM
Droidworks: ooops: Many thanks for your comments I really appreciate it.This project is so awesome to construct I can't stop, in fact even J5 has taken a back seat until I cannot go any further with ED 209.

08-11-2008, 01:54 AM
Decaulkins: The reason I have not put the servos in the head are that I need it to pan and tilt and If the servos are in the head it cannot rotate or move up and down, Also the shoulders will get in the way, I have to clear those as well. I have other items that will go in the head like camera and other electronic gizmo's. Thanks for your input though.

08-11-2008, 06:46 AM
Nice tilt/pan assy to the head Good Job, and dcalkins I think he did this for the outer shell he might put on it to give him some freedom when the shell goes on. That would be one of reasons he would do this instead of putting the servos into the head, Plus he may need that room for the electronics to protect them for being hit.

Edit : I just read his post to you as well sorry!

08-11-2008, 07:08 AM
4mem8, another awesome contraption man...

I'd love to see more of these mechs come together (and should really get started on my own!)

08-11-2008, 07:37 AM
ScuD: Thanks, Yes you should start building yours,I've got it, drop everything and start NOW.

08-11-2008, 07:59 AM
Unfortunately I'm going to Cork next week, have to give some debug training to new employees. That combined with the preparation means I have little to no time in the coming weeks..

08-11-2008, 09:07 AM
I hope you aren't counting on that head to protect valuable electronics and explosive-when-punctured LiPo batteries in the Hardcore Weapon Class....

Just a thought :p

08-11-2008, 02:10 PM
Tyb. Other electronics in the head, Batteries will go [I hope] in the lower section below the head in an carbon casing. Have to start watching weight now.

08-11-2008, 02:22 PM
Still, if youre competing in the hardcore competition with this... that shell isnt going to protect anything. One CO2 powered BB could penetrate that and smash whatever electronics are encased within. It will also likely get pretty maimed within a few matches and ruin the 'pretty factor' of your bot.

Just something to think about.

08-11-2008, 02:30 PM
Coat it with BBB-gone(TM) and it'll be fine!

The risk of it being destroyed in it's first match are high though.. But hey, that's why we invented a camera!

08-11-2008, 02:48 PM
Making molds for ED 209's feet.

I am in the process of making 6 molds for ED 209's feet, this will be constructed from 1.5mm ply and balsa wood, I will go through the process that I do when making model aircraft molds as it is the same process, There will be a number of pics in this section over time as this is a slow process, but the results should look pretty good. The final feet will be cast in carbon fiber with some alloy embedded in the carbon. This will be mainly for hinge points on the feet. I intend for the feet to be sprung loaded.


First we make the base of the feet out of 1.5mm ply x 4 [ two shown ].


Front, back and outer side base feet.


Balsa back uprights for foot.


Balsa back uprights glued to base feet, also not that the plastic feet in the top of pic, my feet are based on this design but wider.


Sanding the right angle, beveled angle comes next.


This was just a base board to get closer to the sanding wheel as we want minimum gap between sander and object being sanded.


Noe sanding the compound angle, balsa is underneath the ply.


Compound angles now done.


Close up of compound angles.


Front balsa now added with the same compound angles.


In place to check fit. These will eventually be hinged.


The sides of the feet extensions are on the out edge only as the feet are to close for inner extensions.


In place for a full shot. Now I need to know what you all think about the side extensions, need them or not?? just front and back?? Don't forget that the feet have to be covered in all round, This is the early stage of making the plugs.

08-11-2008, 03:06 PM
I like the side extensions, makes it look more balanced with the wide parts up top.

08-11-2008, 05:26 PM
I like the side extensions, makes it look more balanced with the wide parts up top.
Agreed, although personally I'd give them a more.. toothed look, kind of like the teeth of a back hoe. Does that make sense? \_/-\_/-\_/ Like that.

08-11-2008, 05:29 PM
the teeth of a back hoe

Uhm... care to explain what a "back hoe" is please, cause I'm... not following.. :eek:

08-11-2008, 06:38 PM
Great work as usual.... breath taking, and I really appreciate seeing each step along the way :) Can't wait to see it in action!


08-11-2008, 08:28 PM
Thanks guys, Electricity" Are you just talking about the side extensions toothed?? if so I tend to agree now.
Crabfu: Your not the only one wanting to see it in action,That's why I am full steam ahead on this project.
Tyberius: I take your point, I will get this bot working first the way I would like it, Then I will make a hybrid molding of the head out of carbon/kevlar hybrid cloth, a co2 bb won't get through that. And if it does I will walk up to your bot and knock you over He he, [just kidding Tyb] The Lipo [If I use one] WILL be housed in Carbon/Kevlar for saftey.

08-11-2008, 10:00 PM
I like the sides too! I think you should keep them if it doesnèt bother the walking gate (like if it's too large)

Great work 4mem8 as usual! You come up with great stuff!

08-11-2008, 11:04 PM
Uhm... care to explain what a "back hoe" is please, cause I'm... not following.. :eek:


English is fun, isn't it? :)

08-12-2008, 01:31 AM
Thanks Sam, I try, That's what makes this forum so interesting, the projects people come up with.

08-12-2008, 03:04 AM
WOW nice work 4mem8! I always liked the biped scout but the custom parts really makes it a exclusive one! Great that you’ve found a model of the ED 209! I’ve searched for some pictures, because it is a while ago since I’ve seen it on the white screen, and you really come close to having a working replica! I would love to see it in action! Keep up the good and inspiring work!


08-12-2008, 04:59 AM
Xan: Many thanks for you comment, I bought a model about 15 yrs ago and have not found one since, It's not meant to be a replica of ED209, but close, I will add some different parts and armour to the front and legs and then a paint job in urban camo.

08-12-2008, 06:39 AM

Front balsa now shaped.


Close up.


The side extensions will be cut in half to form two side feet.


Side extensions now cut in two.


Ready for the next stage, filling in sides of feet.


Sides filled in.


Feet filled in ready for the tops.


Placement of feet extensions.


Close up of mold.


1.5mm ply tops for feet.


Ply tops glued in place and sanded.


In place, the center of the black plate will also be filled in to make the foot look whole.


This stage complete, Shaping now begins and added thin ply for simulated metal panels on top of feet.

08-12-2008, 06:53 AM
I will add some different parts and armour to the front and legs and then a paint job in urban camo.
I saw the paintjob on your Wall-e that's really need! If you gone apply the same quality of paint than this promised to be very cool!

Nice job on the feet! Do you also add a hinge so they are able to bend a little bit when the feet is in the air? (ED 209's toes are able to bend)

08-12-2008, 07:20 AM
Xan: Yes they will bend and hinge.

08-12-2008, 08:45 AM
I really like the double ones on the side!

Are you going to mold them, or are they just going to be like this?

08-12-2008, 02:09 PM
Sam, They will be molded, These are just the plugs, There will also be a plug for the inner foot and the outer feet will attach to the inner section making the feet look more bulky that the thin metal plate you see now.
Look at the head section Sam, you will see a hinge system for a metal cover which is not in place yet, The feet will look like that as far as a hinge system looks.

08-12-2008, 02:46 PM
Will he lift his feet far enough not to trip on his toes? I'm totally not the biped expert...

Spiffy look, though!

08-12-2008, 03:11 PM
4Mem, what are you making the mold out of?
Your projects are great, your photos and splantions make me feel like I am participating! Keep up the great work!

08-12-2008, 08:09 PM
Adrenalynn: I hope so, I looked at some video of the scout that Tyb sent me and in theroy it should,[ But best laid plans] don't always work.
Ooops: The molds will be made out of polyester resin and the final items will be epoxy resin. I am pleased I make you feel you are part of the project.

08-13-2008, 03:24 AM
Hi 4mem8,

I hope that I don’t ask to much, but since you are making pictures of the plugs for the mold. Can you make pictures of the molding process as well? I not fully familiar with the process but I know that you can make really cool parts with it. :veryhappy:

Thanks, Xan

08-13-2008, 03:29 AM
Xan: No problem, I intended to do that anyway, My dedication to robotics here on this forum will cover most of what I know over time to be shared by all.Thanks for asking.

08-13-2008, 04:00 AM
Great! I'm looking forward to see your progress! Thanks for sharing! :happy:

08-13-2008, 06:20 AM
I have done many diffrent trpes of molds and I hav to say the carbon fiber is one that I have not done so I am looking on with intrest in seeing every step of this process. Thanks 4mem8 for sharing your knowledge with all of us.

08-13-2008, 07:27 AM
That's ok guys, I will probably use my vaccum table for the final casting of the carbon parts so as to squeeze most of the resin out. Less weight.

08-13-2008, 08:54 AM
Ohhh, I hadn't thought of that! I was wondering how I could do so that it wouldn't have to much resin. Profesionals use big stoves, but I can't use my stove, it's not good enough. Well, it will give me an excuse for getting a vacum mold. :veryhappy:

08-13-2008, 02:18 PM
Yes, They can be very handy for this type of project Sam.They also have many other uses.

08-15-2008, 05:55 AM
For those of you following this biped more pics will be up this weekend of ED 209, More on the feet design.

08-15-2008, 06:06 AM
:veryhappy: Looking forward to that :veryhappy:

08-15-2008, 12:28 PM
Yeah, me too. I want to see it.

08-15-2008, 04:24 PM
Patience is a virtue, he he.

08-16-2008, 03:51 AM
Update to ED 209 foot molds

Ok, been busy continuing these foot plugs to make carbon molds, I have a number of pics for this today, It's a long process so if you get bored I will understand.


6mm sq spruce, This is really not needed but had it in stock, These have been cut to the bi- ped foot base length and width.


Grease proof paper laid down to glue timber, I will be using cyno here as it is quick.


Set square used to get 90 degrees correct.


Fitted to foot plate to check size.


Frames made and angles marked for sanding.


Angles sanded to match foot front sections.


Front view of angles.


6mm balsa for the tops.


Dremel scroll saw to cut balsa, gives a neat cut.


Cut to shape for top of foot.


After blocks have been glued, Next sand sides to match the front feet.


Fitted in place for a trial fit.


Front and side feet in place for trial fit.


6mm balsa for the rear frames.


Both frames mated for fitting, We have to do two halves here so that we can slide them together from front and rear.


Another trial fit after shaping.


More shaping.


A bit more tricky, now filling in the angle corner where the side feet meet.


Shaping taking place.


Again fitted to check sections.


Starting to look the part, Still a lot of work to do though.

Do you think I should cut the rear feet smaller in length?? Thoughts please

More tomorrow.

08-16-2008, 09:01 AM
I like the design of the feet, but they do seem a bit long now that you mention it.

08-16-2008, 09:24 AM
I love it, but I think that if the toe would be closer to the servo it would look a bit better. But that would be hard to do since you have the limit of the metal foot in your way.


08-16-2008, 09:28 AM
I might have a look at it in the morning guys, Thanks for your input.

08-16-2008, 12:21 PM
I think that if the toe would be closer to the servo it would look a bit better. But that would be hard to do since you have the limit of the metal foot in your way.

You could cut the foot up some. Is the toe actually going to be providing any support or is it for looks only?

08-16-2008, 04:20 PM
sthmck: both really, the toes will be hinged to conform with terrain, I was thinking of using a type of flat spring like material as a hinge so that it can bend both ways and also be fairly rigded for support as well.

08-16-2008, 10:28 PM
I really appreciate your extraordinary effort when documenting your projects. You go well beyond the call of duty and it's so informative for the kids at home.

08-16-2008, 11:13 PM
Hey thanks metaform3d appreciated, This is what I do though, I like to document everything I do, good or bad, like now, It is general consensus both here and R/C forum that my feet are to big, So I have reduced the side and back length of the feet and have to agree that they look much better.

08-16-2008, 11:20 PM
ED 209 feet reduction.

I have reduced my feet by half on the sides and back due to popular demand ha ha, I have to agree it does look better.


Back feet reduced by half and steeper angle.


Side feet also reduced by half and steeper angle.


More in proportion now.


Front view, Thanks guys, Tyberious and GWJax for pointing this out, sometimes you get a one track mind and don't see the obvious.

08-17-2008, 03:11 AM
It does look better - and I really have to agree with Meta on the kudos!

08-17-2008, 03:33 AM
Thanks Adrenalynn, This site and it's members means a lot to me and if I can repay by putting up detailed pics so be it, It's not only for my record but for the other members as well. I just hope I don't bore you all with all the pics I post. I do plan to upload them as a tutorial when all the projects are finished, but that could be a while as i have three on the go and a forth one in the process.

08-17-2008, 08:38 AM
I love project threads that include pictures! It really helps, sometimes you have trouble visualising the robot.

I also like that there is more than one picture, so that we can see it in different angles! It's true! The feet look better now!

08-17-2008, 02:10 PM
Thanks Sam, What project or projects do you have on the go Sam? If you have some I'd love to see them.

08-17-2008, 02:44 PM
Well now I am working only on air muscles. And a way to control them. I'm trying to figure out how to connect BS2 to my PC. Seems like all I need is to conenct the 4 first pins.:tongue:


08-17-2008, 02:55 PM
Just posted to your thread Sam

08-17-2008, 02:58 PM
I'm thinking of raising the head on Ed 209 by 1.5 " to clear the shoulder servos for pan/tilt clearance This would also give a better perspective relating to head and shoulders. Thoughts please.

08-17-2008, 03:40 PM
I'm thinking of raising the head on Ed 209 by 1.5 " to clear the shoulder servos for pan/tilt clearance This would also give a better perspective relating to head and shoulders. Thoughts please.

If adjusting the hight wouldn't throw off his COG much then I'd say do it. Range of visability is more imortant with these MECHs I'd think.

All your stuff looks great by the way! :happy: I'm kinda' in the same boat as I'm more of a hardware/fabricator as well. Question - is your 209 head made of urethane?

08-18-2008, 01:24 AM
BauerMech: Tempted to raise the head, Yes the head is urethane at present, I want to get Ed 209 walking first and then when I am happy with it I will do a hybred carbon/kevlar casting to protect the electronics in the head, same with the lipo batteries on the chest area.

08-23-2008, 02:59 AM
Update Ed 209 scout

Ok, I have finished the carving of the feet and now it's time to seal and undercoat the ply and balsa in preparation for mold making.


Ready for added simulated balsa metal panels.


Simulated balsa panels now added.


Panels in place on feet.


Back of feet.


Full shot of feet.


Front/side view.


Front view.


Ok, I need you opinions here, I intend to raise the head by 1.25" this is to clear the shoulders in pan/tlit mode also I have aligned the head with the shoulders, This mod is also for better front armour panels.


Perspex plate to hold Ed head, A better fixing than before.


This and the rest of the photo's are of the head extended by 1.25", Your feed back would be appreciated in this mod, Thanks.






And the final pic for ya. Till next time.

08-23-2008, 06:10 AM
I'm surprised because I liked it before, but I really like it with the head higher. It gives a better proportion between the sleek sculpted parts and the more blocky brackets.

08-23-2008, 06:18 AM
Thanks metaform3d: Your input is appreciated, Sometime one can get side tracked and not sure if it is the right thing to do, I know I have to clear the shoulder arm brackets in the pan/tilt mode, but at the same time I do not want it out of proportion. or top heavy. thanks.

08-23-2008, 12:13 PM
It's a matter of taste, so go with what you think. Personally I come down on the flip-side. I think it makes it look unbalanced and clunky where before I thought it was really well scaled. [shrug] That's why it's not a group project. ;)

08-23-2008, 12:34 PM
I like it.. It was great on the short side, It's great a little taller. The pan and tilt help with the coolness also. Even if the extra height makes it a little more unstable, those feet should help with that prob.


08-23-2008, 12:48 PM
Personally I liked it better before now that I see it. That piece on the original ED-209 was a torso, not a head.

08-23-2008, 04:49 PM
Tyberius, That is quite true it is a torso, but lends it's self well to a head in this Mech, It was never intended to replicate the ED 209 Mech but look something similar, It appears that we have mixed answers to whether it is good or bad, Thanks for your input people I will see how it goes and looks when body armour starts to be added, I can always change it before I get to the upper torso body armour section.

08-23-2008, 08:20 PM
I'm kinda leanig towards looked better before, but I love the pan/tilt on the head. It might look even better once the front armor gets installed. It also make sense to raise the head to add clearance for impact sensors. Great progress really cool looking bot.


08-23-2008, 08:34 PM
Hey Matt, Thanks for the input here, decisions decisions.

08-25-2008, 10:13 AM
very cool machine. I really cant wait to see it in motion. ed209 has been one of my favorite robots ever since I first laid eyes on if. Just for kicks you should make it talk and sound just like the one from the movie. I remember thinking to myself that if I ever saw one of those i real life I would be scared to death.

08-25-2008, 03:05 PM
Yeah I agree Matt, Maybe I will, But first to get this sucker mobile, which could be tricky for me, but we will see how we go.[You have 5 seconds to comply.]

08-25-2008, 05:39 PM
I love the last pic where it's looking at the table! It looks alive. I love the new pan and tilt. Indeed if the armor is a bit bigger, it could help make the head look lower than it actualy is.

[4 Seconds]

08-25-2008, 08:27 PM
It looks like the raising of the head by 1.25" has the thumbs up so will go with it for now, I can always change it at a later stage if it does not work out. Thanks for all those that replied back. For or against. [3 seconds to comply]