Saturday, April 07, 2007

Recut Center Foot Again, Started Cutting Foot Shells for Drive Train

More help from my friends today.

First, Matthew Henricks came through again for me with some more high-quality plywood for the rebuild of the center foot. Thank you again Matthew!

Mike helped for the three millionth time, this time with the rebuild of the center foot, and the start of the cuts on the foot shell for the drivetrain. Fortunately, my unintentional buffoonery usually makes Mike laugh, so he's somewhat entertained.

Stop me if you've heard this story before... I cut the basic pieces for the center foot on the table saw and miter saw.

Then Mike did the dado cuts that hold the channel pieces.

Meanwhile, Mike had all of about five minutes to work on his own building activities. He ordered some incomplete battery boxes from Craig, and is finishing them himself.

While we were waiting for the glue to dry on my center foot, we started cutting into one of the outer foot shells, since the drivetrain will not fit within them. The drivetrain will continue into the battery box. Mike and I both worked on cutting the foot shell.

If I look like I'm going to puke, it's because the thought of accidentally destroying months of work with a bad cut on the Dremel makes me nauseous.

Next, Mike attached the casters. It is a really tight fit inside the foot shell, so the casters have to be mounted very precisely.

It's so snug in the foot shell, Mike had to grind off some of the overhang of the caster mount plate. More cool sparks!

As we wrapped up, we started checking to see if we could drill the ankle bolt hole. Unfortunately, we ran into some trouble. The blueprints call for the ankle bolt hole to be 0.625" from the tip of the ankle, but it really needs to be closer to the tip (say, 0.500") for my 1/8" thick foot shells. So I'm going to have to figure out how to get a bolt into the foot shell without hacking too much of the shell, and verify that the foot will tilt at the 18 degree angle. If it doesn't, then some minor hacking is in store for the center leg. I really hope it doesn't come to that, though.

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