I’m going to begin my Legs project by making an acrylic Template. This template will then be used to finish the ply-wood layers on my router table. I considered printing out a full-scale drawing based on the Club Blueprints to transfer to my template material but instead I did a new drawing with all the important dimensions in place, and used that to layout the leg outline by hand on my template material.
In my past post I talked about making a Template for my wooden legs. The idea was that I’d rough cut the patterns, and then use the template to finish the pieces on my router table. Well, as Adam Savage says, “No plan survives first contact with implementation”. I’ll get back to this later. I am using Baltic Birch Plywood for these legs, in 12mm and 18mm thickness. Note: Yes, I may speak in the sensible measurement scale (metric) sometimes… I’ll go back and forth between fractional inches and metric on a whim. This is a byproduct of growing up during the metrification of Canada in the early 70s. If you’re lucky (or not) you may even catch me measuring by Smoot… but I digress…
I printed an ABS template for the bolt pattern (Legs, through Shoulder Flanges to Frame) which I used to transfer the center points for the bolts which are evenly spaced on a 5” radius. The Legs were drilled out on the Drill Press, using some jigging to keep things square and true. The bolt holes were counter-sunk on the outside surface. I also used a 2.5” Hole Saw and my Plunge Router for the clearance hole for the Shoulder Hubs, which should really have been done before the glue-up of the pieces.
As soon as I got my Skins molds in hand and the weather here in BC warmed up a bit, I got to making Skins. For R6-T3x, I planned on Bonded Composite Skins and a minimalistic Frame. These skins are quite rigid, and don’t need a conventional frame. In fact, I’m convinced that I could get away with no frame at all which is why I have been experimenting with a uni-body idea over in the Body and Frame forum. But, I was antsy to get going on 6-T3x and had not finished a design that I was confident in the Legs attachment, so I compromised for this build. I used the methods I was happy with so far; Bonded Skins with Top Ring and full bottom, but open holes for the Shoulder Flanges. Keeping in mind that at this point I still was not sure if 6-T3x was going to be static or have a foot drive system, I chose to build a minimal frame which will be rigid enough to keep the legs straight.
The skirt is another plan gone awry. I had decided that I was going to model, mold and cast in composites a Skirt. I considered a Wood Model, and I considered Foam, and I considered modeling clay over a Wood Armature. In the end I decided to model the Skirt in CAD and print it out in pieces out of ABS, weld the pieces and prepare for molding. So far So good... right?