Horseshoe No2 takes a bit more shape

This work I did last month, but forgot to post to Blog.

So I finished glueing the two sections together, then glued in the dowels to locate the horseshoe to the leg. Next wood filler was applied all over the join lines.

Then light sanding and a bit more filler.

Next was drilling holes. I marked the position of the shoulder Buttons [these fit in the square sockets] and also the Hydraulic Unit. The top Button has to be angled slightly, as per the plans, but also for screen accuracy :). So a small strip on hardboard was trimmed and glued in place at the bottom edge of the socket. Although this wont be seen, I'll apply wood filler to blend it in.

Here you see the Horseshoe with it's first coat of primer. Still a bit to do tho. But need to get the Dome finished.

Horseshoe No2 [for Leg No1]

Lunchtime I got to cutting out the slot for the Hydraulic Unit.

Drilled single hole, then threaded through the Coping Saw and got .....erm....sawing. lol

Next, glued the two sections together and apply more wood filler.

Leg No.2 - Horseshoe No.1 complete

Other little bits of work that have slipped through the net

I masked off and silver sprayed the grooves on my shoulder horseshoe. I then sprayed it up white. With hind sight, these will be done after spraying them up white first! Still, they look good :) Next up was to clear spray and dirty up the crevices etc & then I fitted the buttons and hydraulic back on.

I drilled and tapped the second set of shoulder buttons and hydraulic. I just need to make the horseshoe for them to fit into.

Leg No.2 - Horseshoe No.1 - 1.6

Drilled out the fixing holes in the horseshoe already there, to pushfit in the dowel pegs.
Here it is test fited in place along with it's other components.

Leg No.2 - Horseshoe No.1 - 1.5

Drilled clearance holes in the back pieces of the horseshoe. This will allow the bolt heads to be recessed inside, to clamp the hydraulic in place. 

I cut these bolts tooooo short, so will be using others lol.

Have also done two of the four buttons. [drilled & thread tapped them]

The top 'button' is slightly angled upwards. So i cut a small piece of hardboard & glued it in at the bottom of where the hole would be. I'll then fill in to form the angle. I also marked where the holes are to be drilled for the buttons.

Small piece of wood placed to start my angled face

Applied wood filler around the inside of the recess, sanded and repeated......

Also applied wood filler around the outside to start to build up areas.

Shoulder Hydraulic location pins

Eariler today, a two minute job of shaping these two dowels to fit in the Shoulder Hydraulic Units, to secure them in place.

Of course, yet to see if this idea will work or whether they need to be metal pins ???

Shoulder Hydraulics no2 completed

Forgot to mention, that I'd also completed the second Shoulder Hydraulic last week too.

Shoulder Hydraulics no1 completed

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

Already started on the second one lunchtime.

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.

Shoulder Hydraulics

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