I have finally got the build finished today, got the batteries prepared and installed and plugged the charger in and, after reading all the problems people have had, I was pleasantly surprised when it all worked first time. R2 jumped around in patrol mode squealing away to himself. I connected to his internal Wi-Fi and everything seemed to be fine. When I powered him up a second time and tried the projector I have both Luke and Leia playing but no sound, also R2's happy squeals have stopped. I've had him apart again, checked the wiring and plugs but can't get him to make any sounds at all. Could this be a problem with the speaker or is it likely to be something in the head. At the moment I'm telling the family he's in stealth mode.
Merry Christmas to all on here and a special thanks to all the Admin guys for the help and advice they've given everyone.

Make sure you haven't accidentally muted him, in the app features go to settings and you can mute him. I played about with it thinking it was to do with the app and wondered why R2 was suddenly silent

That's great news Mick Hope we get to see some photos
Merry Christmas to you too!