Southern R2 Builders Group Forum Index Southern R2 Builders Group
A Place for Star Wars Fans
 
 FAQFAQ   SearchSearch   MemberlistMemberlist   UsergroupsUsergroups   Join! (free) Join! (free)  
 ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in 

Styrene Outter Feet (Modified for Scooter Motors)
Page 1, 2  Next
 
Post new topic   Reply to topic    Southern R2 Builders Group Forum Index -> Styrene Droid Tutorials
View previous topic :: View next topic  
Author Message
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Wed May 25, 2011 11:22 pm    Post subject: Styrene Outter Feet (Modified for Scooter Motors)  Reply with quote

I'm going to start this Tutorial, Due to the fact that I'm confident the design will work without any problems. Even with this being said: I would wait until the final part of this Tutorial is complete and tested.
Most of the parts have not been Modified to build Dave's Outter Feet just moved into different locations. I have added a few tricks to get the Scooter Motors to fit.
I'm currently waiting on the Drive Belts to arrive so I can test the feet and give it the OK.
You will find as you build the feet there is no room for mistakes and everything fits like a glove.
Make sure you build on a flat surface and keep every part square.
Take your time with this build or you will have problems.
Calvin

***Note**
Do to the fact these feet where never designed for the Scooter Motors,
I have found that the Battery Boxes will have to be 1 inch longer than normal. It's not any change in the size of the foot, Just the fact that the Scooter Motors take up more room than the Jaycar Motor.
Or you can shift the Battery Boxes back further on the foot, But I recommend longer Boxes.

***Complete***
The foot is completed now and it works and is very strong.
I'll work on completing the Tutorial.


Last edited by admin on Thu Jun 23, 2011 11:51 pm; edited 2 times in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Wed May 25, 2011 11:53 pm    Post subject: Reply with quote

1st Cut up the Ankle Slot Channel parts from Dave's plans.
I suggest cutting completely through the Styrene, This will leave clean edges that will not need sanding, Also DO NOT BEVEL THE EDGES as in Dave's Plans. I will tell you why as we go through the build.
After you have them cut, Use a bolt to assist in the alignment as stated by Dave. Use a small bolt about 1/8 in diameter, This will not leave room for mistakes and slop as a larger bolt will do.



Use Weldon to bond the 2 side plates together and use the bolt to get it aligned correctly.



Now bond the 2 part side plate to the bottom plate, Use Dave's bevel line as a guide to set the 2 part plate side to side.
Make sure you square every part!!!
The Metal plates I'm using are only to hold the parts in place.
Once this side has dried, Glue on the opposite  single layer side making sure the bolt is in place to keep the alignment correct.



Last edited by admin on Fri May 27, 2011 4:51 pm; edited 1 time in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Thu May 26, 2011 12:17 am    Post subject: Reply with quote

DO NOT CUT OUT THE AREA WHERE DAVE'S MOTOR WAS PLANNED!!!
Once the Channel has fully dried, You can add the 1st Main Plate.
Please excuse my scribbling, It was just me thinking with my pencil.
From here on I won't remind you to keep everything square.
And don't worry about the bevel on the channel yet.



THINGS START MOVING NOW!!!!

The 2 plates from Dave's plan are the same size just relocated for the Scooter Motors.



Here's the measurement I used to relocate the 2 plates.
2-7/16 seems to be the magic number.
The measurement is taken from the sharp point to the side of the Plates on each end of the Main Plate.
Let this fully dry.



Now you can cut the Scooter Motor Holes.
The best way I found to get the hole in the correct position is to set the 3-1/8 hole saw
down into the area for cutting. It should almost touch the bottom and the Plate you just installed. The hole is larger than the Scooter Motor and if you need to trim the hole, It can be done later.
These 3 pictures should help explain.







Last edited by admin on Tue May 31, 2011 7:55 pm; edited 2 times in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Thu May 26, 2011 12:56 am    Post subject: Reply with quote

Working on the opposite site, Use Dave's parts in the relocated spot.
Remember which foot you are building and build the second foot in reverse or you will have 2 feet for the same side.

The Battery Box side of the foot, The 1st plate is measured at 5-13/16 from the Main Plate point to the side of the new plate.
This will allow the Scooter Motor room and fit in the foot.



Add the 2nd plate from the rear point of the Main Plate to the side of this new plate at 3-9/16.
Add the 2 top plates to each of the new side plates and allow this to dry.



I know the picture shows the bottom plate, But this is not bonded yet.
We will cover this soon.


Last edited by admin on Mon May 30, 2011 10:59 pm; edited 2 times in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Thu May 26, 2011 1:30 am    Post subject: Reply with quote

The large flat plate that is the Main Bottom of the feet will need to be beveled as Dave has in the plan.
Add to your assembly a Side Plate between the 2 Dave Plates as shown in the picture. The measurement for the plate is: 2-1/8 x 8-5/16
To get the correct depth for this plate. Set the assembly on a flat surface and slide the plate between the 2 side plates and when the top edge is flush with the edge of the side plates bond it in place.



Now set the entire assembly on top of the Main Bottom Plate.
Square the assembly with the bottom plate as best you can. You can use the bevel edges to help square, But DO NOT BOND YET!!!!
Outline the entire Assembly, This will make it easy to put it back after you modify the Bottom Plate.
It should look like this:



In the area opposite from the Battery Box side, You will have a boxed area.
This is where the wheel will set. Mark this area with a pencil and remove the assembly so you can cut out this area.
It will look like this once your finished.



Now Bond the assembly to the Bottom Plate and let dry.
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Fri May 27, 2011 4:14 pm    Post subject: Reply with quote

On the Battery Box side, You will glue the next Main Plate.
Go ahead and drill the Ankle Bolt hole just as Dave said in his Tutorial before you glue the Plate.
This Plate sets right on top of the notch that was created when you glued in the lower Battery Box Plates. Use the Bolt hole to align the Plate into position.
Allow this to dry and re-drill completely through the Ankle Bolt Holes with
a 5/16 drill bit. This is the size bolt I'm using, The Droid is so light weight you won't need more than 5/16.
The 2 Top Plates can be bonded into place also.
The only side that I beveled on the 2 Top Plates was the smaller Top Plate opposite from the Battery Box. The others will get beveled soon.



Now using a Mouse Sander, Sand down the front keeping your Mouse flat against the 2 Larger Main Plates. Take your time and this will bevel the Lower Flat area of the Ankle Channel, 2 Top Plate and will leave you with perfect joints.
Also sand the sides of the Ankle Area near the top where the 2 Top Plates meet with a Sanding Stick. DO NOT SAND the Battery Box Side in the picture above, The small HANGOVER is needed later in the build.



Last edited by admin on Fri May 27, 2011 4:36 pm; edited 1 time in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Fri May 27, 2011 4:33 pm    Post subject: Reply with quote

This part is alittle confusing, But I will do my best to show how to cut the Motor Hole through the Side Plate.
Using a 3-1/8 Hole Saw, Slide it up to the area on the Battery Box side of the foot. Mark a pencil mark around the Hole Saw, This will have to be cut out using a Dremel.






In the Picture above you can see I added a Small Plate that measures 5-1/4 x 1-3/4, This gives the Axle area more strength. You can Cut and Bond it into place.
Also in the 1st picture the Battery Box side in the Axle area will get 2 Plates that measure
4-1/8 x 1-3/4, This also beefs up the Axle area.


Last edited by admin on Tue May 31, 2011 8:01 pm; edited 2 times in total
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Fri May 27, 2011 5:19 pm    Post subject: Reply with quote

DO NOT BEVEL ANY OF THESE PLATES!!!
Bond on the Front and Back Facial Plates.
On a flat surface, Even them up side to side. There is a scratch line from Dave that will help you line up the Plates. Pay close attention to the area where the Front and Back Plate meet at the top corner. This needs to be flush at this corner of the Small Top Plate and The Front/Rear Plate so you will have a clean joint.
You will have some overhang at the top and in the Ankle area. This is normal.
Allow this to fully dry.
Once dry, Sand the top of the Front/Back Plates smooth with the top plates and sand the Ankle area.
This will leave you with a a tight smooth joints.



On the Battery Box side,
Skin this area.
Now sand this area flat, There should not be much to sand.
You just want to get it flat and smooth.
BE CAREFUL NOT TO SAND THE SLOPE OUT OF THE  FRONT/BACK FACIALS!!!
Then re-trim the Motor Hole with a Dremel.

Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sat May 28, 2011 10:34 pm    Post subject: Reply with quote

I'm going to leave this post, So I can come back and edit it for the measurements of the Wheel Axle Holes.
I'll have the measurement in about 1 week so you may want to start building the other foot up to this point.
The Belt has arrived and it has been tested and all works GREAT!!!!!!
I'll finish the Tutorial as if we have done the Axle Holes and are ready to move on.
Calvin
Back to top
View user's profile Send private message Send e-mail Visit poster's website
admin
Site Admin


Joined: 23 Aug 2010
Posts: 330
Location: Jacksonville, Florida

PostPosted: Sat May 28, 2011 11:44 pm    Post subject: Reply with quote

Add the Motor Support Plate and there is 2 Plates in this area.
The first Plate measures 3-3/8 x 1-3/8. Make sure you fit it up into the angled corner of the foot. You can see the Second Plate how it fits on top on the 1st Plate. It measures 3-3/8 x 2-1/2. This will space the motor to the correct depth and it also has 1 bolt from the Motor so the entire load is not on 1 single area.



You can see how the Motor will set once we get the foot ready.
Those 3 Motor Bolt Holes you have been seeing for awhile are no Good.
It was my 1st attempt.



Now add a Small Plate to the Motor Mount area. The measurement is
3 x 2. This adds to the strength of this area and you can also see how the Motor bolts to both Plates.
Here again, I'll have to get the measurements for the bolt holes.



Back to top
View user's profile Send private message Send e-mail Visit poster's website
Display posts from previous:   
Post new topic   Reply to topic    Southern R2 Builders Group Forum Index -> Styrene Droid Tutorials All times are GMT
Page 1, 2  Next
Page 1 of 2

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

Card File  Gallery  Forum Archive
Powered by phpBB © 2001, 2002 phpBB Group
BlackAndWhite style created by feather inju
Create your own free forum | Buy a domain to use with your forum