Here is the outer foot shell and the scooter motor frame (striped down and Moded). When I make the Center foot shell I'll take more pics. The outers were made spur of the moment, and I didn't have a camera with me.
The foot shells are made from old computer cases, not the cheap ones these things are 1/32" ish thick. I laid out the pattern on the case and added tabs (to be folded in so I had something to spot wield too.) Then they were cutout a sheet metal cutter (I'll get a pic off this next time too) and a air power nibbler made short work of the cutting. Then a vise , sheet metal Piers and some spare steel blocks and the bending was done. All in all it took about 5.5-6.75 hrs to make two of these (first one took 75% of that time).
The frame here is still a work in progress. The support brackets on the top of it need adjusted to fit the foot, I still need to cut a slot in the top of the foot shells and put some u channel in there so I can attach the ankle to the foot. Once the channel is in the brackets will be adjusted and welded in place.
This is how the motor Mount will sit in the foot shell.
And a look at it from the inside (the part of the foot closest to R2's body)
Back to work!