New frame assembly continues

Over the past two nights I have been piecing together the new frame for my original R2.  As I mentioned, it has been thru two owners before landing here and as a result, some pieces are missing.

Today the spacers and dowels I needed arrived from McMaster Carr.  These are the spacers that go from the bottom frame ring to the bottom box as well as those that hold the utility arms.  I also ordered some dowel pins.

The one oddity has been the block that goes on the bottom of the battery plate, where the center ankle connects.  This isn't the original block, it doesn't even come close to the hole pattern on the plate.  On the left is what came with this frame, on the right is what came with the original v5 Frame for my other R2.

The solution will be to use the correct one as a template and drill & tap the 1/4 20 thread holes needed.

Overhauling R2-D2 begins

Today, the v5 JAG Frame I bought from another builder arrived today.  This is identical to what I bought for my second R2-D2 project.  

The frame is missing a few minor pieces, such as some spacers and dowel pings, but nothing I can't replace locally or on-line via McMaster-Carr.

Here's a bunch of pictures showing the assembly process from tonight.  More soon!

Here's what a JAG v5 frame looks like un-assembled

Bottom plate, the holes on the bottom have already been countersunk

Threaded studs in the front and back, side pieces bolted in.

Long vertical rods are in

Side pieces are in.  The big trick here is to make sure the shoulder stops are facing the right way

Top ring in

I saved one of these when Jerry offered them....fold out electronics tray for the frame

Mostly assembled now...

I haven't decided how "quickly" I will try to move things from my existing R2 into the new frame.  The electronics portion will be the most intense part.  But, I may just take my time making sure I have a good plan thought out before doing so.

Tomorrow I'll work on the rest of the frame, getting the battery holder installed with the correct spacers.