Collar & Radar Assembly

Greg Logue makes an outstanding collar for the club. If you have a club torso I highly recommend you get his collar unless you just want to make your own. It is truly a work of art. However, I have a replica torso so my club collar is slightly taller and wider than the replica’s collar. The replica torso with the replica collar is to the left. My replica torso with the club collar is to the right. Most people probably wouldn’t notice the difference unless you had the replica collar side by side.
Specifically, the original collar from the series (I would assume the replica collar is the same) had ribs that were only 3.625″ tall as compared to the club collar which is 4″ tall. It would be nice if the 8 people who got in on the tremendous deal from Mike Joyce months ago for the replica torso & donut could combine forces (I mean resources) to make our own version of the replica collar. If anyone knows of any extra replica collars made then please feel free to let me know. I would most definitely buy one!!
I obtained my radar from Norm Sockwell as well. He did an excellent job of making it. He even assembled it for me since I had surgery on my hand for tendon repair and reconstruction. In preparing to mount the radar for movement I needed to drill mounting holes to mount the 9″ rockler bearing. The club collar holes were designed for the 12″ rockler bearing. I then cut (4) 1.5″ diameter acrylic tubes to the proper height for a smooth rotation of the radar assembly. I would suggest you plastic weld the tube to the radar section and then drill and tap the rods for attachment to the rockler bearing. The collar will also need to be modified to hold the servo motor that actually rotates the radar assembly. The gearing I used was the 9″ internal gear with the new small cog put out by Andrew Schwartz. You will need to use this one if you are using my bubble lifter so the neck shaft will fit and function freely. Below is the gear and the servo used (a JR DS8711 Robotic Servo).


This Radar is the latest version and is what is going on my replica torso. It is correctly sized to fit the replica collar and Torso. (the club collar is 4″ thick the new size is 3.625″ thick (and a little narrower). As you can see with this picture, the clutch pack has a tapered top. A top view shows a milled out key area for the bubble lifter (never mind the slight dent off to the right of the key – it was a mistake but it will be covered up with the bubble lifter boot cover so it doesn’t matter. Also note the 2nd half of the radar has upper and lower base plates where the ears are inserted.

Underneath the radar unit I have places for the motor drive unit so the radar can be turned remotely or automatically as well as places for the electronics for the ear sensor motors.

And of course here is the Bubble lifter tube with the key inserted. I have included the drawing
so you can assemble your own.

B9 Electronics: The Inside Story Part 5 – Radar Section

My radar section uses the B9 creations’ 2.5v regulated power supply and the Namiki Ear Motors for the ear sensors. Both of which were obtained from Eric Johnson from the club website. The Namiki motors are very sensitive to voltage and you can burn them out easily. The radar is moved by a digital robotic high power JR servo (JR DS8711). The range of movement is 180 degrees. 90 to the left and 90 to the right. I can fit a 360 degree servo in there or I could use a sailing wench servo for continuous rotation but most shots from the series do not show the radar moving greater than 90 degrees because the rotation of the radar section was controlled by Bob Mays head movement, so I decided to stick with that. I would suggest that you use a geared motor to rotate the radar section if you want to have 360 degree movement. However, in order to do that you would need to have a motor controller to be able to direct the degree and direction of rotation. That just means more money and more stuff to cram into the collar/radar area.
I also experimented with IR (infrared) sensors in the collar to direct movement of the radar when the robot is in animatronic mode to further simulate AI (artificial intelligence). The device I used was from Jim Shima’s website called Hyperdyne and These are the same controller cards that the R2D2 group uses for automatic dome rotation in relation to sound and IR movement detection. It works most of the time so long as you are not in a very loud or hot room. That is not always possible at a convention. Also, since the detectors are in the collar you have to be at least 48″ tall for it to detect you. So what I decided to do was put in a IR detector in the rear vent bay to detect those pesky little carbon based replacements we call children. When it detects someone close it triggers a voice message saying to please stand clear and to step away from the rear vent and power pack.