Thursday, October 6, 2011

Starting Work On The Ankle Pieces

We had an off-schedule build night tonight. Clay and I worked on fixing the battery box sides now that the CNC has been re-leveled.

I bought an 8' long 6" diameter Tape-Ease Half Cylinder (the smallest amount I could purchase) and a 2'x2' sheet of 1/4" plywood from Lowe's to make outer and inner ankle pieces. We used club plans and Victor Franco's tutorial for this project. It took us awhile to figure out how to cut the half tubes with the equipment we had. We also ran into a little snag because part of the half cylinder was a little more flat than the other.

We ended up using a chop saw for all of the cutting. We cut three 4 1/8" length outer ankle pieces and three 4" length inner ankle pieces. The half cylinders have a height of 3". The outer ankle requires a cylinder height of 1 3/8" and the inner ankle requires a height of 1 1/4". We cut these pieces slightly bigger and used the sander to smooth out the edges and get them to the right height.

Once at the correct height, we angled the chop saw and cut a 55 degree angle off each ankle piece. We laid the slanted portion of the ankle piece on the flat 1/4" plywood, drew an over sized half circle, and then cut it out. The half circle was glued to the slanted portion of the ankle with plenty of overhang on each side. The over sized half circle will allow sanding later and still keep the needed angles while allowing the pieces to lay flat on the legs.

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