The first thing we tried was redrilling the ankle bolt hole 1/8" lower. While I didn't hold out much hope that this would solve the lean problem, it would help solve another - that the bolt had trouble fitting through the foot shell door since the hole was so high.
Mike marked the spot to drill, and did the drilling.
I forgot to take a picture of a test fit, but suffice it to say that the lean problem didn't improve much. The protractor shows where the lean should be.
Alright, fine. I knew what I had to do, so I did it.
Well, it leans now.
This means that my droid is out of spec. So is my first droid, and I haven't been cast out yet. I've even seen pictures of a Lucasfilm droid that has the curved area of the ankle squared off.
I JB Welded the flange back in the hole.
The hacked leg got the Evercoat treatment, followed by a coat of white primer. I can't use gray primer now, since I can't easily hit the spots that were hacked.
I'll probably clean this up just a little more, paint it, and call it done.
I really don't know what went wrong, as all the parts are to club spec, but for whatever reason things didn't come together like I hoped they would. Oh well.
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