Installing the dome drive!

Today was a rather productive day. I started by drilling the inner dome to start getting it ready for all the accessories like the HPs, PSIs, and Logics. Tons of small holes are drilled around the outlines and will eventually be cut out with a dremel, a file, and a lot of love! Next, it was time to start mounting the dome drive. The drive I have was made by Daren, and is very nice. I started by counter-sinking some holes in my JAG frame. Next, I screwed the dome drive into the frame. In this shot, you can see how I secured the spring. I did a washer, then a nut, the spring, and then two more nuts. Next, I wanted to go ahead and install the nylon ring into the inner dome. To get the ring to fit, I had to make a small cut (about 1") into the inner dome so that it would slide over the ring..... Here, you can see how the dome fits on the angle ring after it's been installed. PROTIP: Do NOT place your nylon ring entirely on your rockler bearing until you are ready to MOUNT it. It is damn near impossible to remove once it's on there. Here, you can see how the cut fits around the ring. My plan here, is to put one counter-sunk screw on each side of the cuts. Then, put one every 90 degrees going around the dome, essentially counter-sinking 5 screws into the dome. Here, I got my rockler bearing installed so that the dome can be installed. However, I do not want to put it on there yet because I still need to drill out a lot of holes. However, I needed to place the nylon ring in there for support when cutting out pieces on the side. I was going to finish counter-sinking the holes in the dome, HOWEVER, I do not have a drill-bit small enough for these screws. So tomorrow, I need to go to Home Depot or Lowe's and pick up a small torx head bit. I also need to get some reinforced Dremel discs so that I can finish cutting the inner dome parts. The JAG aluminum skirt should be here soon, and I am slowly working on acquiring three (3) aluminum HPs.

Trimming the dome.

Today, I was able to get the inner dome trimmed. I started by putting a small gap ABOVE and BELOW the gap (about a quarter's width). Then, I drew a line all around the dome where I wanted to make my cut. I next took my dremel, and scored the entire dome along the line. I made a cut that went all the way through my dome, then took my hacksaw and WD-40 and went to work. About a hour and a half later, I made it about 4-5 inches around the dome......not very good progress!! Luckily, Cobalt60 from the forums recommended using some tin snips to cut the dome. I paid $9.00 for a set of aircraft grade snips at Lowe's......and I had the whole dome done in 10 minutes. Here are some photos showing this progress. Here, you can see the inner dome sitting on my pool table. It's extremely flat, which is something I am proud of! Next, I added the blue ring, and placed the outer dome on it as well. You can see the small gap, but when the blue ring is raised a little, you'll be able to fit a quarter above and below the blue gap. Here is another shot of the same thing, just with more blue panels! On today's list, I plan to countersink some holes in the inner dome, and hopefully get it mounted to the rockler. We shall see.

Also.....

Also, I want to add that in the next few weeks, the JAG Aluminum Skirt should be arriving, which will make for a FUN day!! I also decided to go ahead and get the aluminum center vents, so they will be arriving soon as well. Now I need to pick up a set of Skin Snaps and R2 will really start coming together.

I'm BACK in the saddle again!

While I have been gone from the R2 building community for awhile, my efforts are finally back on the right track. A LOT has happened in the last few months that'd make about any man say the hell with it, but I still give it my all, and know that soon things will be back to normal. Anyway, in an attempt to clear my head recently, I said why not do something that makes you enjoy yourself some....and then I saw poor untouched R2 sitting in the corner, and decided he needed to get back into the spotlight. So to start with, I dismembered all the skins, and primed them with self etching primer! Then of course, came the Rustoleum Satin White......I wasn't sure how much to use to attain full coverage, and in the end, used damn near 2-cans worth! After that was done, I decided to start painting some of the dome panels. I still need quite a bit to finish the dome, including the Teece's kit, the Holoprojectors, logics, and maybe something else, but either way, the blue can start going on.....I used Sonic Blue Pearl, straight from the can. Once the blue had dried, and was clear coated, I had to test it on the dome to see what it looked like. This was really the first time R2 got some color to him and started to look like.....well, R2! Next, it was time to enjoy the fruits of my labor, painting these skins and panels took place over about 4 days, and well, it's time to see if R2 looks like himself. So I started by laying all the parts out. And then, using Scotch Blue Tape, I taped some pieces together, and taped them to my frame to get a good look! And finally, I had to place one of the doors on him so I could see how he'd look with the panels, and this is my favorite shot of R2 so far......you can really tell he is starting to take on a new life!

work on the front skins!

Small update, but I have successfully removed all panels from the front skins. The doors have not been JB welded yet, but I did get all of the tabs filed off and the area nice and smooth. Once a nice day gets here, I may be able to actually get them painted. Furthermore, still awaiting on 3 parts to arrive....

1. Aluminum LDP (large data port)
2. Aluminum PSI diffuser kit.
3. Aluminum Skirt.

The skirt is still a couple months away, but it will be great to see it here! The LDP is also once I am very excited for.

I am planning to order a set of skin snaps soon, which will assist in getting the skins ON the aluminum frame, what a great day that will be!

Sorry for the delay!

I paid $500 (yes!) for a JAG V4 frame, that included the satellite motors for the 2-3-2, the shoulder hubs, speaker mounts, and best of all, the rockler bearing. I have no pictures of this (as I am at work now) but tonight I promise I will update and get some photos.

In other news, I also ordered the JAG aluminum skirt....I didn't need one, but I took money I had been saving for something special, and decided to splurge!!

Pics soon!

edit:

Here is a pic from my phone.

Skin work!

Today I started the process out cutting out the outer layer of skins. I only did the back side today to make sure I had a firm grasp on the process. Truthfully, if I am going to mess a side up, i'd rather it be the back. Fortunately, and this kills the drama, I didn't mess anything up!

Here you can see that I have most of the panels removed. These panels come out just like the dome and the inner skins......a hacksaw and a little WD-40. Once they're out, I take a file and get them nice and smooth.



Here you can see my new table for holding parts!


Here is a shot (another one) of how I remove the panels that I don't need. In this case, the inside part of the door. By placing a piece of wood underneath it, it raises the piece up a small bit, and helps with the removal. Simply place a chisel on the line, and give it one firm hit!



Next,I take the pieces inside and match up the panels from the OUTER and INNER skin.


Here you can see each inner panel resting on top of the outer panel.



Next, it's time to place some JB WELD on the outer door panel. What I did, was place the doors on top of each other, drew a line with a sharpie along the edge of the doors, then put the JB right on that line.

PROTIP: JB Weld is MESSY! Especially for a first timer. I used a box of Alcohol Swabs to help clean up any runs that drifted into a spot that would be seen. These pads worked wonderfully!



Next up, it was time to clamp the piece together. I bought a package of 200 (YES 200!!!) at walmart for $8.00. This is how many I used on ONE piece.



And finally, an hour later, I had all 6 panels JB Welded and clamped! They look phenomenal.



In other news, despite my best efforts of holding off, I bit the bullet and purchased a JAG Aluminum Skirt today. There was nothing wrong with my MDF skirt, but I just had to get the aluminum one......!