Finally got to the painting stage.  This was done after all the part's had been assembled and R2 had a couple of test drives.  I did that to make sure everything fit prior to paint as I did not want to be drilling holes in fresh paint!

04/10/07 : A picture of one leg finished and painted.  I find with painting
these parts, waiting a week or more will keep the damage from handling
the parts down to a minimum.


04/05/07 : Dupli-Color DAP 1689 sandable primer applied over the
Tempo zinc chromate primer.  Next step, Krider blue.


04/05/07 : Preparation of Horseshoes.  Sanded the Dupli-Color sandable primer with 600
grit sandpaper.  Then went over the whole thing with a tack cloth prior to the Krider paint...
Taped off area's are to show the bare aluminum when Buttons and Hydro's are installed :)


04/06/07 : Ankle Cylinders and Wedges finished with Krider paint method.


04/05/07 : Booster Covers primed with Tempo zinc chromate paint.  Next step: Dupli-Color
sandable primer.


04/05/07 : Booster Covers after Krider paint was applied.  I used white glue in the 'slots' to
help remove the blue to show the raw aluminum...


04/09/07 : Ankles, Ankle Cylinders and Ankle Details and outer Cylinder Holders (Thanks Jerry!)
finally assembled.

I have an old version of JAG's aluminum outer legs.  They do not come with the 'slots' that match with the slot in the Booster Covers.  I used a Dremel and a straight edge as a mini-mill to make the groves.  I also had to cut the keyholes that are used to mount the Booster Covers.

04/04/07 : Picture showing tool used to cut the lower leg slots.  I bought a Dremel cutter bit
that just happened to measure 0.100 diameter, the specified slot width!

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04/02/07 : First, had to determine just where the holes needed to be then mark and center-punch
the leg prior to drilling out the holes for the Under Shoulder Details.  I drilled straight then tilted
the drill to match the angle of the parts once installed.


4/02/07 : Under Shoulder Detail "mounted".  Not quite sure how I'm going to secure these.

I purchased the newer extended Booster Covers (BC) from Droid Stuff.com.  They are the newer
lighter weight units.  I notice right away a problem, JAG's outer leg drawing shows the vertical
mounting holes to be 11.00" and the Droid Stuff BC's were drilled at 11.25".  My JAG aluminum
legs were the older version without any keyholes cut, so I was safe.  Not sure what builders that
have the keyholes already cut are going to do... there is enough room to re-drill and tap new
upper mounting holes.  The bottom holes are to specification.

03/08/07 : Here shows the vertical hole measurement.  Does not match JAG's drawings...  I assume
builders with pre-key holed JAG legs could drill and tap a new hole 1/4" down.  The BOTTOM
mounting holes were fine...


03/08/07 : Two of the Key Holes drilled.  Now to file between the holes to create the Key Hole.
These happen to be the bottom key holes.  Make sure you accurately mark and drill the holes
or the BC's will not fit!


03/08/07 : Finished lower Key Holes with ankle mounted.  Now there is another problem, there
is a plate in JAG's aluminum ankle that will have to be cut out to allow clearance for the extended
BC!


03/08/07 : Ankle plate cut.  Cutout is approximately 1.400" deep by  3.400" wide.  Cut with a
dremel cut-off disk and grinding bit.


NOW : Onto actual Booster Cover and Leg Strut mounting.

03/08/07 : Of course, now the lower Leg Strut tube had to be lengthened.
I got lucky, found some 0.75 " round stock.  I used a hand drill to drill the
0.50" hole in the top and the hole in the bottom of the Strut Tube that was
tapped for a 10/32 screw.


03/08/07 : Here shows the new Extended Booster Cover, original
upper Leg Strut part, new extended lower Leg Strut tube and spring
plus lower Leg Strut mounting plate and screws.  The spring goes into
the hole between the upper Leg Strut tube and the lower Leg Strut
tubing... this puts pressure on the Leg Strut assembly holding it in place.


03/08/07 : Tapping 10-32UNC holes in the bottom of the BC''s


03/08/07 : Bottom view of the Leg Tube/Strut assembly showing home-made mounting plate.


03/08/07 : Here is the BC and Leg Strut assembly completed and ready to mount to the leg.
You can see a more detailed mounting instructions at Jerry's (JAG)s site at: JAG's Booster Tutorial


03/08/07 : Here is a shot of the two different Ankle Bracelets.  The one on the left is for a "flush"
BC mount, comes as a standard part with JAG's aluminum legs.  The one on the right was sent
to me by Shaggy (THANKS MAN!).  Not sure what run it's from, but you can see the difference
in the cutouts, allowing the Booster Cover and the Leg Strut to pass through instead of just
stopping flush with the top of the left Ankle Bracelet..


03/08/07 : Finally, BC and Leg Strut Mounted!


03/08/07 : Closeup shot of the new Ankle Bracelet, neat!  Thanks Shag for the Ankle Bracelets!


Still have to find a way to mount the Ankle Bracelets...

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The Horseshoe Shims from Mr. Roboto needed quite a bit of cleanup prior to use.  I used
a palm sander and 220 grit sand paper and smoothed out the metal.  Then sanded out the
inner and outer edges as these will be seen once assembled.  4 holes in each shim need
to be counter sunk to accept 10-32 flat head (FH) stainless steel screws.

Initial test fit/layout. It is best to center the inner holes, then check outside alignment.  Carefully
clamp, mark and drill.


Here the two shims have been prepped and 4 holes each counter sunk.


After carefully locating/centering the shims on each leg, the 4 holes were transfered to leg itself.
A 10-32 tap was then used to tap each hole.


Horseshoes mounted.


CENTER ANKLE MOUNTING
I then installed Guy Averett's center Ankle Mounting block into the center ankle.  You can get this
and other parts at Atomic Pickle.