Ankle Locks

Since Im using a single caster on the middle foot i need to lock it from pivoting. I just took some 1/4" aluminum and cut out some wedges to lock it in place.

To make the template i held up a piece of card stock level with the top of the foot and took a pencil and rubbed along the edge of the ankle radius. This transferred the curve perfectly. Then cut and traced that onto the aluminum and cut with a band saw. Next i smoothed and adjusted with belt sander.

Then i just tapped a hole in the ankle and attached. Seems to work quite nicely. No play either way.

Ill do a little more trimming to make it pretty.

HE STANDS!!!!

Test fitting some leg parts. 

Had to cut, drill, and tap a center ankle addapter.

He Stands for the first time!!!

Wood legs.

I got some cnc cut legs from R2-ATL run to hold me till i get some alum together. These are great legs and ill stick them on a second droid at some point so they wont go to waste :)


Ready to glue up... Note that slot at the bottom for wires goes to the back.

All glued up with a little sanding.

Time for some bondo. Most recommend evercoat instead but i didn't want to wait for shipping. However i used the higher quality bondo gold. It goes on much smoother than regular bondo.

Next glued on the beefy ankles with some liquid nails. I just used tape to hold it overnight. Seems pretty strong. I have a full set of jag ankles and  I was tempted to just cut off the wood ankles and secure them to the alum ankles but this way when i get my aluminum legs together ill have two full sets of legs and ankles.

Little more bondo and some primer... Then i hit it with some 400 grit and painted white. Don't have pics of that yet tho.

Oops also had to cut the slots in the legs. I used the milling machine for this.