Monday, October 6, 2008

Example #2, door construction

Here is a larger door. The aluminum angle is riveted to the hinge side back of the door. The rows of rivets are counter sunk within one centimeter from the edge of the door. This method will allow the outer skin layer to cover the rivets, Use a good quality contact cement on both the door and vinyl outer skin, allow to dry, then press together.
The result will be a great looking, functional and solid door.

Sunday, October 5, 2008

Door fitted and finished you can see how the door looks after being fitted with the outer skin made from a vertical blind... I set in into the utility arm bay to see how it looks...

Saturday, October 4, 2008

Assembling the equipment bay doors

The doors are made as follows:
sand all edges of the door panel, then cut 1/4" aluminum angle to length of each door. on the hinge side, clamp the angle 2 millimeters from the inside edge.
drill 1/8" inch holes down the angle, and through the PVC door. Next, using a large drill bit, carefully counter-sink the hole on the outside of the panel, use aluminum countersink pull-rivets to fasten the angle to the door. The angle will be used later to attach the pushrod horn and hinges for door actuation.

Cutting out more holes

a quick shot of the progress on the body skin. the holes being cut out for more aluminum parts and "droid hardware"

Back after a long break

Moving took a lot of work and getting settled meant I had to take a break from building R2D2...The project is back in business now, in the next pic, is the hand made aluminum coin slot for the front of the droid...It is made very easily from thin aluminum and glued to the skin.