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Legs-2 |
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Shoulder cutouts done with a saber saw and straight edge. Cut-outs have a floor made up with 1/8" mdf skinned with .020" styrene |
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Upper left-shoulder shim. Lower left-shoulder indexed to leg by drilling through center point. Drill bit installed to locate shoulder assembly congruent with the leg assembly. Stacked assembly is taken to disk sander to insure a perfect match. Upper right, finished shoulder, inside portion cut out with saber saw and then taken to drill press drum sander to complete inside circle portion. Lower right-leg with upper blocking installed. Slot routed down center of blocking for electrical wiring to Saturn motors |
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Leg Construction Continued: |
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This shows the legs joined up with the ankles. Notice the chases which have been routed into the legs and ankles for the motor wiring. |
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This shows how it all goes together following the attachment of the leg outer cover pieces. Legs, ankles and detail pieces. |
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The cutout for the alum. hub is done with a sabresaw and finished on the drill press drum sanders. |
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Here we have the hub in place. (The wings will be added later) |
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Here we have the 6.66 pvc coupler. On right, coupler has been cut into correct widths. |
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Left: my old router compass finally came in handy. Test cuts made on scrap wood. Center: this shows correct grooves routed into the legs using the compass. Groove is .250 deep and 6.66 in diameter. Right: 4.5 aluminum plates cut, recesses routed into inside of legs. |
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On the left, we see couplers and mounting plates in place. The aluminum plate is used as a template to locate leg mounting holes which are then drilled with a small drill. A forstner bit is used to recess the holes on the outside and then the through holes are drilled to .250 |
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The shoulders are clamped to the legs and taken to the drill press where |
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6 small locating holes are drilled thru to the leg. The assembly is separated, |
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the holes enlarged to accept magnets and locating dowels. The dowels index |
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the shoulder to the leg perfectly each time it is installed. |
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On the left, we see a paper template which is used to transfer hole locations to the |
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booster covers and legs. Again, holes for magnets and locating dowels are placed. |
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On the left is the 1/8 mdf shim which has been covered with monokote. Middle- |
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detail leg pocket. Right-leg skinned with details in place. Shim can be seen as well. |