July 26, 2011

Centre Leg - curved section idea update.....

Was thinking about the curved sections for R5's centre leg, and that my first plan to carve them out of solid [in my previous post], although genious :-D lol, was also flawed. The fact that it was going to take me ages to make up all four, cut/screw/sand to shape etc... But more importantly, they were going to just add to the weight of R5!! So scanning through my web page favorites, I remembered seeing this idea on  http://podpadstudior6.blogspot.com/ build. Where he used a curved piece of scored hardboard to form the shape. So I will be attempting this way of building them instead.


Check out BOTH builds here:  http://podpadstudior6.blogspot.com/ & http://podpadstudior9.blogspot.com/

July 25, 2011

Shoulder Hydraulics no1 completed

Finished off machining the flats onto the sides of the Shoulder Hydraulic.



Already started on the second one lunchtime.

July 24, 2011

Work so far.... Shoulder Hydraulic and Centre Leg work

Friday in work: I milled flat the rear of the shoulder hydraulic unit. Also drilled two location holes, for fixing it with dowels into the shoulder hourse shoes. 0.25hr (20mins).

I off-set the top location hole on purpose ;-D


Then at home I drilled the bolt holes in the seconed shoulder disc. Sanded the wood filler on its edge. Extended the clearance in the underside of the top ring so shoulder disc fitted correctly. (1hr)
Next I marked the position of centre leg. Drilled out then cleaned edges with file & dremel with sanding wheel. A nice snug fit.  Need to find some more aluminium angle, to secure leg in place. (1.5hrs)

Saturday 23.07.11
How to make the radi parts of leg? Have seen a few ingenious ways from being shaped from solid block to frame work with sanded wood filler.

I started of with the idea of building up the curved section, which would then be filled in & sanded curved to finish. This was gona take a long time, then I found a piece of wood that when cut correctly, would be just right, to complete the curved section. Just needs a few saw cuts & shaped with a file.

July 22, 2011

R5's Centre Leg, work started

Started work on the centre leg yesterday evening. Had to us two thickness of wood to make up the correct thickness. A template was used to mark the out-lines. I then drilled & used 'screwing screws', screwed the two pieces together, then cut out with a jigsaw. Repeated this twice more for the side parts. Then removed the 'securing screws' & fixed all three parts together with longer ones.


Need to sand some surfaces and then use filler next.
Time taken = 2.5hrs

July 20, 2011

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Shoulder Hydraulics

Started now on the Shoulder Hydraulics. Will turn it as one piece and then Mill the flats onto it.

R5's Rear Dome Rod

Not been able to get on the Milling machine, so started on machined up the rear Dome Rod, in two parts.



Only have the Shoulder Hydraulics & Stabilisers left to machine up.

July 15, 2011

Booster Leg Strut No 2 - UPDATE

Finished turning the lower section and the two parts are now assembled.


Have turned, on the lathe, the top part and marked it ready to be milled square. Onced I've milled the flats, I can then drill the hole. Job done!

R5's Skirt update


Cut out the rest of the skirt pieces. After positioning them I measured the gaps & marked up the flat pieces that fit in between. Next, I marked the skirts position on the base & drilled holes for screwing it to the base. glue & screw them all together. Secured the MDF angles using car body resin.

Spent an hour with wood filler, then sanding, spray primeing (to show where extra filler was needed), then more wood filler. Looks a bit rough but that will just add to the 'worn' look of R5.

July 13, 2011

Shoulder Disc - No.2

At the weekend I cut out the two additional shoulder discs I needed to build up as spacers [three in total]. Drilled and screwed them together. Then turned them to right size on the Lathe in work. I need to drill out the bolt hole locations and extra holes to reduce some weight.

Next I need more wood filler, sand smoooooth and spray.

Booster Leg Strut No 2

Yesterday I started on machining up the second Leg Strut. Finished the upper section. And have now started on machining the lower section. All out of Aluminium.

July 09, 2011

M10 Threaded Rod

Whilst in Wickes, I thought I'd check out prices for bolts needed to secure R5's legs to his body. First packet I found was for only four bolts/washers/nuts! [I need 10 in total] at nearly £5. Then I saw these.....

So if I cant find any other M10 studding, I'll be back for these.

Lower Vent Surround cardboard test internals

Lower vent, cardboard internals mock-up.

Made this up to check the fit for my custom made vent surrounds.
Have started on the metal version. Post pics soon.

Booster Leg Strut No1 complete


the squaqe top part of R5's leg strut. I used the lathe to turn the top diameter and undercut (groove). Then used the Milling machine to mill the four flats and drill the connecting angled hole.

Finished


After machining the top section to correct length, first leg strut complete. Next, strut no.2.

July 06, 2011

Booster Leg Strut's Upper & Lower pieces assembled

Drilled out the lower piece to accept the upper section. Next is to make the square section.

Lower section, I used scotch brite to dull the Aluminium.

July 05, 2011

Booster Leg Strut's:

Found some material, so these were the next pieces to be machined up. Redrew them up with metric dimensions. So they were easier to read for machining purposes. [as the dimensions were not all grouped together] And finally because they will be made in three parts.

Started on turning first part of 'leg strut'. This part fits inside the leg booster cover.

I made it longer at both ends so it will slide into the other parts.

I must point out that this multi-part construction is not my 'idea' but borrowed from [web pages]. Also, due to size of available scrap material.


Also, sketched up how I am going to make the square top part of R5's leg strut.

Basicaly, I'll use the lathe to turn the top diameter and undercut (groove). Then use the Milling machine to mill the four flats, than drill the connecting hole.

Lower Front Vent Surround:

Finished off machine milling the lower Vent Surround. Internal & external shaped, angle on back face done. Edges removed, polished up a bit. Next, internals to build.