In this tutorial, We will build the Outer Ankles for your Droid.
After you have cut and etched all the parts needed to build the ankle this is where you will start Bonding.
1st bond the 4 layers of the ankle together using Weldon 3.
Allow these to dry. I also noticed when layering plates together they never
seem to be the exact same size. (Maybe it's just me)
Next, Bond the 4 smaller plates to the larger plates.
This will give you the correct thickness of 1 inch.
Add the 2 large beveled sides on top of the 4 large plates.
Try to keep everything square and allow drying time for the Weldon 3.
Add the cross member and the 2 lower sides.
Add the 2 small plates on top of the 4 small plates.
These also get bonded to the cross member for strength.
We can also go ahead and bond the 2 inner side plates.
These are the ones with the small clamps are holding in place.
1 inner plate per side.
Allow all this to dry overnight, You will need to sand the top of these plates to get everything flat and level. In Dave's plans he explains why this must be done. If you skip the sanding, Your next plates will not set flat and this could cause the ankle to break apart.
Now bond the 2 plates on top of the ankle verticals.
Now that the Ankle is built and all it needs now is skinning and adding the Beefy Ankle hump to the front.
I have a Drum Sander that a bought from Harbor Freight and it really helps with squaring up the sides.
It cuts the styrene so you get a better fit for the skins. It's not something you have to do, But it really is worth the extra effort.
After you sand the Ankle you can skin the sides.
Here's where I do things a little different than Dave shows in his plans.
I like to overcut the skins and I use my Dremel to cut it back close to the main ankle then sand it down flat with a Mouse Sander. This gives me the best edges I could hope to get. You can use Dave's skin file and just cut out past the line or I get allot of extra styrene from other areas and they can be used to skin different items.
In this picture you can see how I bonded the skins and you can see the overhang.
I used the same idea for skinning the lower area also.
This picture shows how it looks after it's skinned and sanded.
Start adding the rounded top plate for the Beefy Ankle area.
Keep everything as square as you can. Then add the flat plate and the next rounded plate. Here again I do this different than Dave does in his plans.
Next Bond in the little brace between the 2 round plates
Add the small triangle to the lower rounded plate and check the fit of the skin going on top of both rounded plates.
Now bond the skin plate on top of the rounded plates and make sure each end meets the edge of the ankle. You may have to tape each side down to hold as you bond it with Weldon 3. In a earlier set we added the skin to the side of the ankle and here again is something I do different than Dave.
Once the Beefy Ankle Skin glue has dried, I sand the sides to make sure the skin doesn't fit past the edge. I then add another skin on the sides on top of the 1st layer skin. This skin I overcut just like the 1st one, But now the Beefy Ankle Skin is in place when I sand the new skin it gives the Beefy Ankle skin something to but up against and when you sand this time you get a perfect joint and a stronger joint.
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