More Foot Work

Rounding out the weekend, I decided to work on the feet some more. I marked out the holes in the side of the foot shells for the motor mounts. I then cut the holes out using my Dremel. I then mounted the motor mounts and marked and drilled the holes to mount them to the foot shells.


I decided to also take a look at the under the shoulder details. I drilled a small hole to tap a threaded rod into. I will cut a hole in the legs to allow me to use a wing nut to attach the detail to the legs.

Booster Mounting

Toady I decided to mount eh booster covers on the legs. I have some older legs that do not have the keyhole slots sut in them, so I had to make my own mounting system. First I fitted everything together and marked out where the boosters sit on the leg. I used the center strut as a guide.


Next I measured where the holes where on the booster and marked them on the legs.

I then double checked my measurements with the blueprints and I even put a piece of paper on the boosters and punched holes in it where the screws go. I then lined the paper on the legs, just to triple check everything. I drilled the holes for the screws and then drilled a larger hole .375 inches above the smaller ones. I used a small thin hack saw blade to cut teh connecting piece between the two holes. Once I had a channel between the two holes I filed the channel flat.

Large Data Port

I had a few panels on the skins pop off, so I cleaned them up and re JB Welded them on.

i also took the frame apart and looked at the large data port slot. Thsi slot need to be cut to allow the piece to sit further back. I took the top most horizontal piece off the Utility Arm carrier and then put the LDP into the opening. I clamped the LDP ontot he top ring and marked the cut. I now just have to cut the frame. Looks like it is time for reciprocating saw to come out.

Foot Work

I need to cut the holes for the foot motors. I started marking out the hole on the foot shell and took out the handy Dremel. I almost finished the first one before I had to stop for the night.

No pictures yet... I so covered in metal filings, slag, and pieces of cutting disk that i didn't want that all over the camera.

Rear Door Attachment

I started attaching the rear Door to the back of the droid. I am still waiting on some magnets, but I fashioned a "channel" for the top of the skins to slide into. I used some scrape pieces of skin since they had the correct curvature. I JB Welded them onto the top and will attach the bottom of the skins with magnets. The top slides on perfect.

A Labor of Love

I realy thought that the skins would all be done today... BUT I had an issue come up last night an I was only able to get a few of the remaining panels on. I only have 3 more panels to attach and the skins, minus the doors, will be done. I am kind of burned out on skins at the moment and looking back I probably should have worked on somethign else after doing the rears. There is much innovative stuff to doing the skins, but, file, glue, then clamp. At least this weekend I will be able to move on to mounting brackets, feet, and the dome. I haven't really decided on what to do next. I may move onto the mounting brackets to get some skin panels attached. I do have to cut the holes for the feet as well. I probably will do a little of both. I have some ideas on mounting the detail pieces, but we will have to see.

Skin Me

1 more night and the skins will be done, except for the doors. Tonight The front skins got one last filing and then were JB Welded together.


I actually used every single clamp I have and I could still have used a few more. I went the JB Weld route on the front because there aren't too many panels like the rear door to apply JB Weld from the rear to fix any issues. So now I am covered in JB Weld marks, but the skins are almost done. I used the coins slots to help align the skins, but once the skins were clamped I removed them. Toothpicks make great helpers in clamping the skins between the coin slot openings.

I also foudn some spots where the rear door was pulling apart. I clamped it together and applied some JB Weld to hold the pieces together.