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Styrene Outter Feet (Modified for Scooter Motors)
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Joined: 23 Aug 2010
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Location: Jacksonville, Florida

PostPosted: Sun May 29, 2011 12:40 am    Post subject:  Reply with quote

Add the thin Strip that Dave say's not to throw away to the bottom of the foot on the Battery Box side. After it dries, Sand the Curved supports to match the areas where they join.



Now we can Skin the Battery Box side of the foot. I used some thin Styrene that was probly .20, It was half the thickness of the Body Skin which are .40.
Cut a sheet larger than the area to cover and wet the flat area of the foot and the Curved Main runners and apply the thin Styrene.
When wetting the foot with Weldon, Just run wiggly lines all over the flat area but don't over do it and hold the Styrene down with just enough pressure to keep it in place and message the flat area to get the Weldon to spread.
Having help with this part makes it much easier.
After it tacks up, Run a small amount around all the edges so they will not peel up. It sounds harder than it really is.
Here's what you should have:



After the Weldon has dried you can actually trim around the foot with a pair of scissors. Don't try to trim to close, Just get some of the excess Styrene out of the way.
Now sand with your Mouse Sander and this is how it will look.



After the Sanding, Apply another sheet of Styrene on top of the 1st.
This will make the area strong, Just be easy on the Weldon so it doesn't burn through the .20 Styrene. Do all the edges with Weldon and after it dries, Sand the Styrene just like you did the 1st and it should look AWESOME!!!!
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admin
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PostPosted: Sun May 29, 2011 10:23 pm    Post subject: Reply with quote

Now we can close the Door Side of the foot.

In Dave's plan he uses different size Styrene sheets to get the correct look, But I wanted the side to be as strong as the rest of the foot.
I used 3mm to build the Side Panel.
1st lay the foot on some Styrene and trace around to give you the general shape needed to close the side then cut it out.



Using that old cheap Krazy Glue with a brush you get at Walmart,
Put a little on the end of the foot and adjust the Side Panel to fit.
Let the glue dry and this will give you a temporary bond so you can sand the sides of the Panel to fit the foot perfectly. The Krazy Glue can now be popped apart and the panel is ready for the next step.



Last edited by admin on Tue May 31, 2011 8:09 pm; edited 1 time in total
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admin
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Joined: 23 Aug 2010
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Location: Jacksonville, Florida

PostPosted: Sun May 29, 2011 10:53 pm    Post subject: Reply with quote

Tack spray Dave's Side Panel Print onto some .40 Skin Styrene.



Cut off the outer Band and it should fit the 3mm Side Plate.
It will need some sanding but not right now.



Now cut off the skinny band and this is the Plate to save in the Picture.



Lay the Outer Band on a flat surface and then lay the Side Panel Plate on top of it. Square it up the best you can, All the way around.
Then run the Weldon all around the outer sides.



This creates the banded edge around the side of the foot.


After it sets a few minutes, flip it over and run a very small amount of Weldon to the inner edges and put alittle weight in the center to keep it flat and let this dry.



Now to set the Door Panel.
Cut out the panel from Dave's plans and lay it on top of the Side Panel with the edge border. Square it up as good as you can and with a very sharp pencil trace around the Door Panel.



Remove the Door Panel and draw a new line 1/16 inward around the entire Door Panel Trace.





This new Line around the Panel will need to be cut out very carefully.
the Panel will be used for the backer for the Door Panel Skin.
It also will align the Door every time you install it.
This is what you should have now.



Cleanup the edges and place the Door Panel back into the Side Panel Frame. Put Weldon all over the Door  Panel but not close to the edges.
Lay the Door Panel Skin on top of the Panel and align it so it has a even space all around the sides.
Let it set for about 1 minute and ease the panel out of the Frame.
Turn it over and run a very light amount of Weldon around the edges.





Last edited by admin on Tue Jun 28, 2011 8:31 pm; edited 4 times in total
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PostPosted: Fri Jun 24, 2011 12:25 am    Post subject: Reply with quote

Now you have a nice side panel with a opening door that needs to be applied to the foot.
Using tape to hold the Side Panel in place, Apply Weldon around the edges so the panel is bonded.
Let it dry some and remove the access door apply Weldon to the inside edges of the panel. DO NOT LET THE DOOR GET BONDED TO THE SIDE PANEL.



After the Side Panel has fully dried, Sand the sides so the edges fit perfect all the way around the foot.

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admin
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PostPosted: Tue Jun 28, 2011 8:43 pm    Post subject: Reply with quote

Ok, This just about does it for the Foot build.
Sand the foot all over and get the corners real tight and smooth.
Any little imperfections will be hidden by the Skinning Process.
The best way I can tell you about Skinning is to overcut the skin for the area you are Skinning.
Apply Weldon to the foot area and lay the Skin on to the area and just message the Skin to smooth out the Weldon.
Then apply Weldon to all the edges and allow to dry.
Sand each area of Skin with a Mouse Sander with 220 Grit Sand Paper.
Keep the Sander flat and follow each angle of the foot as you sand.

Once you are done Skinning, Use Glazing Putty for small problems then Prime.

Tutorial Finished.

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