[Jacques]

For the larger cracks try and use mesh and epoxy applied from the inside, don't try and glue on the crack edge.

[gijoe77]

I've bought around 5-6 o2's in the past year, almost all of them arrived in pieces. 3D printing is the way to go, but the sort of precision needed is something I'm not sure how to easily accomplish...

[Silicon Classics]

There was a low-poly 3D model of the O2 among the IRIX demos, but it's not accurate or complete enough to use as a basis for fabrication. So we would need to build a 3D model of the skins based on careful measurements (or better, a 3D-scan), then modify it and print it using a metal sintering system, which can create very accurate objects. Somebody used such a system to print a working handgun several years ago.

The skins could be modified for additional stiffness & reinforcement (maybe not necessary if they're going to be metal?) and the locking tabs could be replaced with screws or perhaps redesigned to account for the limited flexibility of metal. We would have to choose a metal that's compatible with the O2 chassis material (steel?) and figure out the best way to prime & paint it to closely match the original colors. Color anodizing might be an option too. We would also have to decide whether to 3D print the CD-ROM drive cover and the fan grille or just go with the base, shell, and top hat.

Metal sintering printers are obviously expensive so the printing would have to be farmed out to a shop and we'd need to figure out the cost, but it probably wouldn't be cheap. I don't know how many collectors would be willing to plunk down several hundred dollars to purchase metal skins - there might not be enough interest to justify the expense.

[mamorim01]

Good point on the mesh and epoxy, will do that. I just did a head count and the back of the case is somewhat fixable. It is still a bit messy but this is the only way to move forward as pieces need to be rotated and aligned. 



As for faithfully reproducing the skin through 3D scans and sinterising printers, results would probably be spectacular but the whole ordeal would be quite an undertaking. I still think a compromise solution would be more feasible maybe?

Cheers,

[Intuition]

I feel your pain. My second 02 was shipped badly too. It came busted up shell like yours. 


I was lucky in that it was in less pieces. Like four large bits and about 3 small bits. I was able to super glue them all together then use epoxy in the cracks. Finally did a wave of sanding and  then sprayed it with matte white primer and finally glossed it over. 

I left it white. It looks pretty cool custom now. 

I bought another o2 earlier this year and told him not to ship it. To leave it in his closet and I will pick it up. Didn't want it broken.

Still haven't picked it up yet though.   It is in mint condition though. Can't wait to get it and post pics later this year. Probably Thanksgiving ish.

[jan-jaap]

I bought another o2 earlier this year and [...]  I will pick it up. Didn't want it broken.

Exactly what I did. Cost me 250 or 300km by car, but my blue and purple O2 system are both as good as new.

Come to think of it, I think only my Fuel and my green Octane were shipped to me. I prefer to see things in action before I commit money.

[Irinikus]

I bought another o2 earlier this year and [...]  I will pick it up. Didn't want it broken.

Exactly what I did. Cost me 250 or 300km by car, but my blue and purple O2 system are both as good as new.
Come to think of it, I think only my Fuel and my green Octane were shipped to me. I prefer to see things in action before I commit money.

You’re extremely lucky that you’re located where you are, as I’ve had to import all of my machines!

[BackPlaner]

Much respect to you for even attempting this, much less getting this far!

[Irinikus]

Much respect to you for even attempting this, much less getting this far!

Thanks, it' all for the love of the game! (I truly love these machines!)

One thing that's for sure is that it's really tought me the concept of logistics!

[mamorim01]

It is starting to look okay, all things considered. I should be done with it in a couple of hours as the epoxy sets and I remove excess mesh to tidy things up. I will still need to apply some repair putty on the cracks where the original material had simply disappeared, but that will be postponed, I will see if I can find some which matches the color as much as possible.