ASTROMECH ASSEMBLY

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Not affiliated with Lucasfilm Lt. R2-D2 is the conceptual propety of Lucasfilms and used with out authorization.

My leg/ankle details started as a piece of 1/2" plywood with a 1 mm layer of SINTRA glued on top.   The first step is to layout all the pieces on the plywood using the plans available in the R2 builders archives. You will need four of these, two like fig.1 and two mirrored. The plywood shape will be like fig.1, the top layer of 1 mm SINTRA will look like fig. 2. The rectangle on fig. 2 (section C) is to be cut out of the SINTRA, once glued to the final piece the rectangle will be the recessed detail on the pieces. Once the pieces are laid out, cut out the outer most shape of the plywood pieces using a scroll saw. (Fig. 3) Next, turn the pieces on their side and trim down the thickness of the top most shape of the part (section A) using the scroll saw. Fig. 4 You will need to file the part down after trimming to round the edges of section A.   Next, adjust the "deck" of the scroll saw to cut the angled part of the detail pieces. (Fig. 5)   You will have to reverse the blade to cut two of the pieces. (Fig. 6) (The angled pieces are section B in fig. 1)   Once the plywood is cut and filed down and the SINTRA layer is cut and section C removed you can now glue them together.   Once the pieces are glued and dried sand and seal the wood areas then paint. Once the paint dries, mount the pieces to your legs and sit back and be proud!

Leg/Ankle Details

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 1

Fig. 2