Adam's R2-D2 Droid Pt2

Month 4 - June 2008
Disc of MDF cut to help locate the bearing centrally	Disc held in place with a single bolt at the center, the bearing then fits over it	Bearing is bolted to the top of the frame and the MDF disc removed	Cutting the center of the frame top out using the router
Much better for access	Test assembly of leg parts
Month 5 - July 2008
Plastic used to mask off part of the wooden feet	Middle section covered in fibreglass	End parts removed...	... then the ends get covered in fibreglass too.
Wooden parts removed, I am left with a three part mold that bolts together	Outer foot mold with one end off	Outer foot mold ready for use	The molds get fibreglass resin and matting on the inside
Once set the ends of the mold get unbolted and remove easily	The middle section is more stubbon and requires a bit of pressure to release	Outer foot shell, fresh from the mold	Three feet made.
On his feet for the first time	View from the back	Dome needs a bit of work!	Top of the leg booster covers get cut from some MDF offcuts that I've glued together.
All the feet have a lower part to them. These are the sections seen from below	Covered in blue G4 sealer, ready to make molds from	Making the molds	molds removed from the formers
First two lower feet sections, just need another outer foot part making	Lower section joined to the top section	three completed foot shells	Shoulder buttons are turned from solid aluminium
four buttons are needed	buttons go here in the shoulder horseshoes
Month 6 - August 2008
More lathe work	Shoulder hydro is made from a solid bar	Making the hydro supports from more solid metal	Hydro parts
Assembled loosly	Hydros and buttons fit in the recesses in the shoulder horseshoes	Buttons and hydros get fixing bolts threadded into them	Top of a leg strut machined from a solid piece of metal
The leg strut is made in two parts that are screwed together	Top of the strut is a square block	The blocks have a button detail on them	The main part of the leg struts