Leg Booster Unit & 'Dog House' 1.5

Fixed 'dog house' onto booster cover using P40 resin.

Then drilled two counter sunk holes in underside of ankle bracelet. The original plan was to screw up into cover. Changed this to screw down into the ankle block. Next, I marked strut position on bracelet & then drill a 10mm diameter hole for its location stub.

Stub's on both struts needed to be shortened by a few milimeters. This was expected as I didn't know how I was going to fit them in place. There are a few alternative ways on how to secure in place. So the stubs were turned down, on a lathe in work.

Sorted out a spring to take up the gap in the leg section. This will fit between the upper and lower strut sections. Not sure if I will actually need it, at the moment as on test fitting [see below] assembly went well. This will also make assembling a lot easier.

Drilled and tapped M5 into rear of Strut square tops. These are to have M5 Bolts screwed into them. Bent some metal to fit behind the square top block to secure it to it and the leg.

Test fitting of strut. Screw into leg for square top piece support.

Used dremel to cut slots in booster cover. Ooops, the collet came loose & the bit cut too deep at the end of the cut :-( Can be seen in pic below.

Fixed with wood filler, phew (not shown in pic). Marked positions of the four grooves at base of cover.

Then started with dremel, then a round file (below).

Lastly I fitted my dremel up with a sanding wheel and made a start on the top block's curved eadge. (below) This was re-done in resign after the wood attempt failed.

Did some more sanding and filling.