R2server

[crazybillybob]

The next complicated piece that I need for R2 is the Ankles. They need to be very strong as all the weight of R2 is on them and is multiplied several times in a hard turn (hey if he's R/C I want to play!). My solution to this is Fiberglass Reinforced with a 1/4" alum plate on one side and a 1/8" plate on the other side.
In thinking about this I realized that I've got to make a mold for the fiberglass. So I fired up some CAD software and a few hours later, I've got a vertical Mold. In the pics the mold supports are the Green and the ankle is blue. I only drew in the plywood forms, I'll skin the inside with 0.04" Styrene (I've got some extra around here) this way the fiberglass will be nice and smooth.

Now That I have a Plan I can start building the mold. Then Lay more glass!
Keep checking in I'll post more as it's built.

Crazybillybob

[Ascoates]

Wow after wathing this project and others and reading just how much people have said they have learnt I really cant wait till I get money together and start this mod and learn new stuff and see how it turns out.

These forums are trully awesome and I really cant wait till I start.

[Rankenphile]

Oh sure, get all excited now, but don't expect an apology from us when you can't decide if you should spend your money on rent or servos and plexi!

[crazybillybob]

Oh sure, get all excited now, but don't expect an apology from us when you can't decide if you should spend your money on rent or servos and plexi!

Wait, Your supposed to stop and think about it? Hands down the answer is servos and Plexi. Wait that's a trick Question, I don't pay rent I have a mortgage


Crazybillybob

[TheGreatSatan]

Damn! You're one high tech redneck! How the hell are you gonna fabricate that stuff??

[crazybillybob]

Damn! You're one high tech redneck! How the hell are you gonna fabricate that stuff??

With a little "Farmer" Engineering, and my trusty band saw.

Look for an update in the morning and you'll see the start!

Crazybillybob

[crazybillybob]

Yesterday I stopped by ASAP Source They're located just up the road from my office. I was there for cheap Aluminum plates ASAP calls them randoms, really it's just scrap or mistakes from cutting or machining. I picked up 2 6"x9" 1/4" 6061 Aluminum plates, an a 18"x24" 0.08" 3003 sheet for $17us (that's with taxes). I was happy , to top that find off the hobby shop called, I went there looking for retractable landing gear door hinges ( because their designed to allow the door to close flush with the skin of the plane when the hinge is mounted inside the plane), we had to order some and they had came in. So here's my haul form yesterday.

I also started cutting out the plywood supports for the mold (this is how I'm going to fabricate all those lines in the drawing!). I Printed out all the pieces of the forms on paper (from the drawing)

Once it was printed I Sprayed the back of the paper with Spray adhesive.

I left it get tacky (3-5 mins) then stuck it to the 1/4" plywood. A few minutes at the band saw and you have this.

Support ribs for the mold. I need to add some bevels in a few places then all the pieces will be attached to a base board (makes it easy to move around). Once cut and beveled I'll skin the inside of the mold with styrene (it will smooth out allot of the irregularities in my cuts and it bends easier then plywood! I hope to get the mounting and skinning done this weekend but I have an upgrade to do at a plant also this weekend, so I'm not sure how much I'll get done (IE. If the upgrade is smooth I'll get allot done, if it's not ...You will not hear from me till Tuesday or Wednesday! )
I also started laying out the 1/4" Alum reinforcing plate as well.

That's all I completed yesterday!
Crazybillybob

[Rankenphile]

Nice deal on the metal.

Can you show a detail of the hinges? I'm interested to see how they work.

[crazybillybob]

Can you show a detail of the hinges? I'm interested to see how they work.

There is a Closer picture of them sitll in the bag nested under retractable landing gear door hinges in the post (and here). As I have not taken them out of the bag yet, so can't do any better. I was really tempted to open them up last night, but there's some tiny screws and nylon bushings in there, and my one cat runs off with anything not nailed down (for some reason it ends up under couch or dresser? ). But I will make sure there are sevral pics of the hinges (with very good detail). As I need sevral more of these for the rest of the doors on R2 I maybe make some of my own too! So you'll be seeing allot more of them don't worry !

Crazybillybob

[Defyant]

this is how R2 is meant to be built!