The Head

The heads were manufactured by Peteric Engineering, a specialty sports car fabricator, leasing space at Shepperton studios at the time of the production. Peteric manufactured the heads using a plaster sculpt given to them by the prodcution team and likely supplimental production blueprints drawn by Peter Childs.

Although the head is shown as reference on a number of drawings, the master layout is Drawing 60. Drawing 60 is a layout as opposed to a detail drawing and has no dimensions. Drawing 60 references drawing 33 as defining the profile of the dome.

The heads were spun out of aluminum sheet over a wood former. The outer domes were spun first. The wood former was shaved down and then inner domes were formed. The panels were scribed out onto the surface of the spun dome. The panels were drilled and cut out by hand and filed smooth.
 
May 8th 2021
Modeling the Basic Head Features

The Head Datum

The Head/Body interface is defined on drawing 60. The interface is shown as the bottom edge of the blue ring. This is the datum that defines the base of the Head profile. It could be decieving that the plaster Head includes the Alloy Race but closer inspection shows that materila below the blue ring is marked "WASTE.f"

*Image not to scale

The Profile of the Head

The Head is shown on all of the production drawings as being the same diameter as the Body. This would make the minor axis of the profile 9-1/8". Measuring from the bottom edge of the blue ring per the definition on drawing 60, the height of the Head is 10-5/8".

*Image not to scale

 
The Body

The bodies were manufactured by Peteric Engineering, a specialty sports car fabricator, leasing space at Shepperton studios at the time of the production. Peteric manufactured the bodies using the production blueprints drawn by Peter Childs.

Peteric's construction of the bodies was started using production drawings 52, 53, 54, 55, and 56. Shortly after construction started the studio revised the design requiring Peteric to discard all the work that had been completed to that point. The body design was finalized with production drawings 67-1, 67-2, 67-3, 67-4, 68, and 69. The bodies seen in the original film were made meticulously to these drawings.

The body skins were punched on a Strippit 30 ton single station punch single station punch. The machine was programmed using a stylus that would trace a "program" that was drilled into a metal plate. The "program" was mounted onto the stylus tray. Each hole in the "program" was color coded to indicate which die should be used for that particular punch operation.
 
May 4th 2021
Modeling the Basic Body Features

The Final Production Drawing Set

From the front elevation drawing there are 8 drawings that are referenced that are specific to the definition of the body.
  • Drawing 37 - Mechanical Arm Arrangement
  • Drawing 63 - Louvered Intake
  • Drawing 67 - Sheet 1 - Front Elevation
  • Drawing 67 - Sheet 2 - Rear Elevation
  • Drawing 67 - Sheet 3 - Port Elevation*
  • Drawing 67 - Sheet 4 - Starboard Elevation
  • Drawing 68 - Body Setion A-A & Body Section B-B
  • Drawing 69 - Body Setion C-C & Body Section D-D

The OpenR2 digital twin

The drawings do not specify the construction method. From production photos, its documented that the body builds started with a wooden mockup, then progressed to a fiberglass prototype, then was contracted to the discarded aluminum build, and then finally the aluminum build seen in the film.

The production drawings are agnostic of the construction method.

otical For the OpenR2 digital twin, the body will be modeled agnostic to manufacturing. The body model will be a single solid which will drive the downstream blueprints and the downstream models that are specific to a particular construction.

The Body Shape

The body is a cylinder with a height dimensioned at 1' 7-5/8" or 19-5/8". This dimension appears on the front elevation Drawing 67 - Sheet 1.

The theoretical height of the body is measured from the Bottom Ring Assembly to the top of the Leg Assembly. This includes a 1/8" gap between the body and the Alloy Head Race. The practical height of the body not including the gap would be 19-1/2".


The body diameter is dimensioned at 18-1/4". This dimension appears on the cross-sections Drawing 68* and Drawing 69*.

The Body Symmetry

The vertical body symmetry is based on 5-3/4" symmetric and mirrored dimension that defines the opening for the Mechanical Arms in the front of the body as well as the opening for the Removable Back Panel on the rear of the body. This divides the body into four zones of symmetry. This dimension appears on the cross-sections Drawing 68* and Drawing 69*.


The horizontal body systemy is defined by a plan that divides the body into a upper and lower zone. In the front of the body this is lower edge of the Mechanical Arms. In the rear of the body this is the lower edge of the large panel on the Removable Back Panel. The total distance from the theoretical top of the body to this dividing plane is 6". This dimension appears on the front elevation Drawing 67 - Sheet 1 and on rear elevation Drawing 67 - Sheet 2.


The Body Balance

The bodies balance is established by the placement of the Leg Assembly pivot. This pivot is dimension at 4" below the theoretical top of the body. The practical distance to the top edge of the body skin would be 3-7/8". This dimension appears on the front elevation Drawing 67 - Sheet 1.

 
May 7th 2021
Positioning the Body in Space

The Ground Line

The ground line to the bottom of the body measures 11" on drawing 67 sheet 1. This would put the shoulder pivots at 26-5/8" above the ground plane.

*image not to scale

Nuetral Ankle Position

This results in the top of the ankle being positioned on the vertical center of the octagon port and the rest of the lowest row of panels. This respresents the neutral design position of the body when the middle foot is retracted.