Ankle Joints - Where are the wires?

Hex Socket Head Screw Shoulder Screw, Bronze Bushing, Hex Lock Nut

 

Star Wars Celebration Anaheim

Center Foot - Caster Assembly How-To

For the Center Foot, I chose an Albion brand Model 21 Medium Duty Caster (21NG03201S). This caster has a 3" wheel, 4-1/16 x 3-1/8" mounting plate, 1" offset and a height of 4-1/16". Supports a 1200 lb. load and cost $26.

First, I drilled 4 x 5/16" holes in the JAG Caster Bracket plate. Using a medium strength Loctite, I attached  the 4 hex standoffs to the mounting bracket using split-lock washers (star-washers would probably be preferable here) and socket head cap screws. You don't want the hex standoffs to spin if you ever need to remove the bracket plate. Next I installed the caster mounting screws and star washers through the Bracket plate. *Note: These screws mount through the top (or inside) of the plate. I then attached the Half-Moon details through the Caster Bracket using machine screws, flat and split-lock washers. The caster plate is then mounted to the hex standoffs and finally the caster to the plate. *Also Note: The caster must be installed with the foot in it's upright position. Unless the caster mounting bolts are secured, they will simply fall into your foot assembly and you'll need to remove the caster bracket plate and re-assemble. The final result gives the center foot a ground clearance of 7/8".

Installing the Center Foot Caster in a JAG Center Foot using the JAG Center Foot Caster Bracket.

Ultimate Periscope (Periscope Ver. 2)

Just received my new super-awesome Ultimate Periscope from super-awesome club member Michael Wheeler. Beautiful work as always!

Ultimate Periscope and Riser 2012

Below is a comparison between Michael's 2011 version and his new Ultimate periscope. you can see the housing is a bit wider and a bit shorter in the rear, but overall remains very similar. The Periscope also has a few improvements like improved lens retention tapped hole and an optional magnetic pie panel holder. The riser has some major improvements and is extremely screen accurate.

Periscope vs. Ultimate Periscope... Who will Win???

The structure shaft is hollow. (now you can run all your power and programming wires much easier), Instead of O-Rings it has a rubber boot with the spiral pattern. The boot disk floats on top of the rubber boot so you have something to play with and the connector clips have details most people have never seen.

Dome Drive 2.0 - Phase One

Seeing as how I have this lovely new Base Plate... I decided to get to work on Dome Drive "2.0" - I'll be removing the 3.25" Dome Drive Wheel and replacing it with the A&A Geared Dome Ring.

Phase One was to "fix" the Rockler Bearing.

I decided to remove the sluggish greasy grindy loud steel ball bearings and replace them with Teflon coated White Delrin Acetal Resin Ball Bearings.

First I removed the Dome to get at and remove the Rockler Bearing.  Once on my bench, I first removed the small set screw on the side of the bearing.

Bearing Set Screw Removed

Holding the Bearing vertically (Careful! Bearings will start falling out of this hole!) over an empty container I began to spin the bearing and 153 greasy ball bearings spilled out... rather easily however.  You can see the screw here... I also made a small mark with a sharpie on the screw head so I could put it back exactly where it was.

153 Steel Ball Bearings

Once I had the ball bearings removed, the two halves came right apart.  the bearing was loaded with thick lubricating grease, which had to be removed.

I simply used paper towels to wipe the bearing clean. Once the grease was removed, I went ahead and cleaned the bearing with a light spray of WD-40 on a clean rag, making sure I had a nice smooth surface.

Grease Removed and Bearing Cleaned.

Once I had the bearing cleaned up, it was time to install the plastic ball bearings. These are  White Delrin Acetal Resin Ball Bearings in 5/16" diameter.  These come in packs of 100 so I went ahead and bought two so I was sure to have enough.

DuPont Teflon White Lithium Grease & Teflon Silicone Lubricant

First I coated the inner track of the bearing with Teflon White Lithium Grease. Not a lot... just a nice even layer... enough to coat the entire track.  Under the weight of a heavy wooden loaded Lazy Susan, lots of thick lubricating grease is fine... However the aluminum dome is not as heavy and rotation was actually impeded by the heavily greased ball bearings.

White Delrin ® Acetal Resin Balls, 5/16" Diameter

Next, I took 153 of the plastic ball bearings and placed them in a disposable Tupperware container and gave them a light bath in Teflon Silicone Lubricant.  I laid the Bearing flat on my bench, and carefully installed the plastic ball bearings back through the installation hole. Once I was done, I replaced the side screw and tested my new, "improved" Rockler Bearing.

The result?  A dramatic improvement, I have to say!  I'm super happy with the result... about a 400% improvement, by my super-scientific calculation... :oP ...and silky smooth!  R2's head has never spun better!  Not only is this a performance improvement but a fairly significant weight reduction as well...  the steel ball bearings weigh in at almost 1 pound (15.3 oz.) where the plastic bearings come in at a super-light 2.0 oz.!  More to follow...

Dome Base Plate (#6)

I also received a set of Dome Base Plates today from David "Steele" Smith, which included this gorgeous Blue Anodized Diet Dome Base Plate.

Aluminum Dome Base Plate - Blue Anodized

C6 R2 Passes

The bidding was fierce and it was down to the wire, but I scored this baby on eBay for a whopping... five dollars.  :o)

All I need is more R2 tchotchkes, but I just thought this one was cool. (Aren't they all?)

I have my Yoda 4 Day Adult pass from the con, but this one is way 'mo better, methinks. ;o)

CVI 4 Day Child's Pass