Creating your own Tom Servo Robot head can seem daunting, but with the right approach, it’s totally achievable. This guide breaks down the process, focusing on making the head’s components, specifically the barrel and head structure, manageable and fun to build. Let’s dive into how you can construct your own Tom Servo robot head.
Getting Started: The Barrel and Gumball Machine Globe
The foundation of Tom Servo’s head involves a gumball machine globe and a snack dispenser barrel. If you haven’t already, the first step is to detach the black plastic base from the gumball machine. A simple flathead screwdriver will do the trick.
Next, take your snack dispenser, which will serve as the barrel. You’ll need to remove the globe. Using a hacksaw or coping saw, carefully cut off the globe at its base. Once separated, place the globe in a secure location to prevent it from rolling off your workspace and potentially breaking.
Preparing the Upper and Lower Lips
Now, let’s focus on the upper and lower lips of your Tom Servo robot head. You’ll need to carefully remove the upper lip from the gumball machine globe. In some cases, like mine, you might find it’s held in place by a hidden lip within the globe. If it’s stuck, try to gently pry a section loose. If this proves difficult, use a coping saw to make careful slits in the remaining part of the globe. This should allow you to extract the upper lip. Once the upper lip is out, remove the lower lip as well.
With the lower lip detached, the next step is to modify it. You need to cut off the hoop that was originally used to dispense gumballs. Cut it flush with the exposed portion of the mouth, ensuring you only remove the hoop and leave the small protruding “doohickeys” intact. These are essential for keeping the lip properly positioned in the mouth. Before making any cuts, remember to remove the spring and store it safely to avoid accidentally stretching and rendering it unusable.
Priming and Painting the Components
Gather your prepared components: the extra cap, regular cap, gumball machine base, barrel, engine block, and both the upper and lower lips. It’s time to prime them with silver paint.
If you’re using a “Barrel of Monkeys” barrel, you’ll likely need to remove the labels first. The center label should peel off easily without leaving residue. However, the top label might be more stubborn. For any sticky residue, rubbing alcohol can be effective in removing it.
Once the primer is completely dry, it’s time for the color coats. Grab your can of Testor’s Ruby Red Metal Flake (Color 1629). While acknowledging the cost compared to the can’s size, apply a light coat to all the primed parts. Important: Remember to set aside the lower lips at this stage, as they are already painted and do not need the red coat. Give the upper and lower lips another coat of silver for reinforcement, then set the lower lip aside again.
Mask off the area of the upper lip/beak that should remain silver. Then, proceed to paint the rest of the upper lip, along with the other components, in Ruby Red Metal Flake. For the Lazy Susan Bearing, a single coat of ruby red can help it blend in better, although it’s not strictly necessary.
For the red parts, aim for around three coats of the Ruby Red Metal Flake. Keep in mind that applying too many coats can darken the color, potentially shifting your ruby red Tom Servo robot head towards maroon. After applying three coats, flip all the parts over and paint the undersides, excluding the gumball machine itself.
Working on the Head’s Innards
With the gumball machine globe now finished with painting, and while the other parts are drying, we can start working on the internal components of Tom Servo’s head. Drill a small hole near the back of the globe’s roof for a screw eye. Test the fit of the screw eye and then apply hot glue to secure it in place from the outside top of the gumball machine. This area will be covered later, so the glue’s appearance isn’t a concern.
Next, drill another small hole in the back of the lower lip. Attach the lower lip and thread a long piece of high-tension string through the hole in the lip. Tie a couple of knots to secure it, and then run the string through the screw eye. Pull the string a few times, perhaps even saying, “That’s great, now you’ve got my jaw!” to test the jaw mechanism. This setup is how Tom Servo’s mouth will function. Remove the lower jaw temporarily as we move on to preparing the PVC connector.
Preparing the PVC “T” Connector
Now we tackle one of the more unique aspects of the Tom Servo robot head: the PVC “T” connector. This piece needs to fit snugly inside Servo’s head and be level with the base, allowing it to connect to the body rod. You’ll likely need to make adjustments, cutting the PVC pipe multiple times until it matches the desired shape and fits properly inside the gumball machine head. The goal is for it to look similar to the image provided in the original guide, ensuring it fits securely within Servo’s head. Don’t worry about damaging the PVC during this process; it’s quite durable even when cut.
Reinstall the lower jaw into Servo’s head and thread the string through the screw eye and then through the cut opening and threaded hole of the PVC T connector. Test the jaw string to ensure it moves smoothly without obstruction. If it doesn’t, remove the T connector and sand, cut, or file it down until the string moves freely.
If the string rubs against the T connector, it will eventually wear and break. To prevent this, consider running multiple strings through Servo’s head. This approach, which I adopted after experiencing string breakage, distributes tension and ensures that even if one string breaks, the mechanism will continue to function.
During a field repair at Gateway Con 2000, I learned the hard way about the importance of string redundancy when a single string setup failed. Position the T connector as level as possible inside the head to ensure smooth head rotation when attached to Servo’s body. Secure it in place with hot glue, applying a generous amount to fully cover the edges, but be careful to avoid getting glue on any moving parts.
With these steps completed, you’re well on your way to having a fully functional Tom Servo robot head. Remember to let all glued and painted parts dry completely before final assembly.
