Ver 3.2 - Visor Electronics

Well the Futaba linear conversion units were very close, but in the end did not have sufficient travel to fully open and close the visor as I need.

Moving on to an orbital hinge design and Firgelli linear actuators that have a matching stroke and power with enough speed that it won't look stupid :-p

Orbital hinges constructed from a mixture of aircraft grade aluminum and steel.
Will be ordering the Firgelli's in the next month or so.

Ver 3.0 - Visor Electronics

Well, I finally got the linear servo conversion units for the Futaba S148's :-D
 and a hot-rodded Hyperdyne board that allows full voltage to the eye LED arrays and full slew rate to the dual servos!!

The first video describes the layout and geometry and the second one shows it in action...
The beauty of this actuation method is that it can be laid on its side and thereby reduces its overall height almost by half. The second benefit is that it keeps the actuation rods away from the face, minimizing risk of injury.

Now that this is proven, I need to devise a temp placement method into one of the helmets to complete proof of concept once and for all.

Compression Articulations

Well, here are some fully functional compression articulations for both front of elbows and back of knees.
This stuff is very tricky, and requires some serious geometry to get right, without blaring gaps all the while allowing articulation like butter.
In order for it to function properly, it has to either be attached to the armour shells, or an internal metal exo-frame so that it tracks properly.

Ver 2.0 - Hyperdyne controlled Rocket Launcher System debut

Ver 2.2 - ARC Reactor

Ok... been working on my ARC Reactor a bit more.

The LEDs are POWER TOP SMD SMT PLCC-2 1210 3528's

• The board was designed similar to the one that Honus designed.

• I used a silver pen to trace out the circuit lines and voila... a crapload of light with no Paladium poisoning!!!

My good buddy Zabana gave me a spare plexiglass ring which I doubled up my copper wire windings. Unfortunately there is a small size discrepancy between the ring and the LED placement as I had already built it before the ring came in the mail. I can live with that. :-p

• All of the 20 spokes/forks were hand fabricated from 22 gauge steel fitted onto an aluminum center ring

• The upper bridge wirings are actually soldered copper

• The larger central ring is aluminum with the slots all hand punched and cut

• The Tri-arm linking the center piece to the above-mentioned central ring had to be made from steel as aluminum does not take well to complex bending

There are a few more processes left before it is complete, but it is a nice solid piece that I won't be ashamed to wear at a Con.

Flight Test System Configuration2.0

Just thought I would throw this gear up here as well just for fun :-)
It is too cool to just sit there gathering dust !

Ver. 1.2 - Forearm Rocket Platform

This shows the mechanism from the servo side so you can see the action better, and a better view of the polarity changing switch. Think of the rocker switch you use for your power windows in your car. Same deal here. This can also be done by a non-lobotomized servo and a servo controller to give you the exact travel you want from the servo AND it is triggered by a simple tap switch. Touch it once, it goes up, again and it goes back down to rest. I will be doing it this way more than likely, its just that I had these old micros kicking around for the proof of concept.

Ver 1.2 - Forearm Rocket Bay

Ok, video #1 (RocketSystem.mov) shows the prototype for the rocket platform
This was made with scrap parts from my man-cave, and an old servo that I lobotomized, and finally a DPDT switch that is wired to switch polarity. Will provide all schematics for wiring the switch setup, templates for the linkage and how to place the servo.

Ver 2.0 - Visor Electronics

Here is the PCB and a couple of servos "Y" jacked together + DarkJerre LED eyes.
All is activated by a solitary micro tap switch.
PS - The batteries are pretty pooched, but you get the idea...

Ver 1.0 - UnActuated Jarvis visor in action...

 

Visor System

On the linkage:
I have the optimal visor linkage worked out and in place... exactly the same as the Jarvis Helmet.
Very solid movement for sure.

On the visor:
Bear in mind that when the helmet was made, part of its shape and integrity is the front section. When you cut it the helmet will have a tendency to "bulge" outward at the edges of the sides. It is a good idea to thicken the edges of the helmet that you are cutting off. If that's too hard to do, then do the whole helmet. You can always do what I did and Dremel and sand off as much of the faceplate as possible (the inside of course)to make it less heavy so it is easier on the servos to lift.
(Smoothcast 321 and slushcast it)

Servo placement:
Waiting on more details on servo type and placement... will detail more as I get it