The Big Think

April 23, 2016

More R2

Filed under: The R2 Project — jasony @ 9:38 pm

It’s been a busy R2 week! Feels good to get some serious time in on the build. Tonight, after spending 8 hours at Techshop (four of which were teaching a water jet class), Erin and I went out to dinner. While leaving dinner I said “I kinda feel like going to Techshop”. It’s nice that the place has such a good hold on me and I don’t get tired of it.

Now that it looks like I have a handle on the horseshoe I went ahead and cut the rest of the layers (six of them) for the other side. Then I filed off the tabs and ground down the v-grooves on the edges of each. So now I have a second stack of horseshoes all ready to weld! I might hit up Keith again to walk me through it, but this time maybe he’ll let me weld while he advises from the sidelines. I’m about ready to get started TIG welding parts.

Side story: tonight my water jet class had two people in it. Normally it has four. I really like two person classes since I can help the students more and I don’t feel as rushed. One of the men in the class was about 70 years old with a great sense of humor. Funny stories (he was a pilot as well so we could talk endlessly about planes and flying), great sense of humor, and — unusual for someone of that generation — was heavily involved in programming and microcontroller technology. We hit if off immediately and I had a great time teaching him. The only issue was that it was sometimes rather difficult to understand him on account of the fact that half of his face was missing. And one whole eye.

You see, this funny, lighthearted, intelligent septuagenarian is fighting a long battle with cancer. 8 years ago he had a tooth that wouldn’t heal and here, eight years later, he’s had one eye removed, he’s missing the teeth on one side of his head, the entire left side of his face is nearly gone from the cancer, he’s wearing two hearing aids, jokes about his lack of depth perception, and says the hardest part of his life comes every four months when he goes in for his MRI to see if the cancer has returned yet again (it keeps coming back). The hardest wait is between the MRI and waiting to see the doorknob turn and see if his doctor’s face is smiling or ashen. He calls it “getting his ticket punched for another four months”.

And now this guy chooses to spend four hours of his remaining time in my classroom learning how to use the water jet because he wants to be a Techshop member and he wants to use the tools to build cool stuff. He’s not sure if he’ll be here next year, or even six months from now. But with the time he has left he’s going to make stuff, and try to make it well. And I can’t tell you how much I enjoyed getting to know him.

R2 Horseshoe Weld Success!

Filed under: The R2 Project — jasony @ 9:20 am

Some good success today. I coated the horseshoes in JB Weld and LabMetal to fill in the little V-grooves that I ground in each side layer. It was ugly once it dried:

 

IMG 2060

Next I clamped the part in the vice with some wooden shims:

IMG 2062

Then I ground the welds and filler down with an aluminum grinding disk that Keith gave me the other night (thanks, Keith!) They looked really good after I was done. Nice and smooth and flush with the surface. Since I was using a disk and not a belt, though, it was easy to make little divots and gouges in the soft aluminum. There’s a bit of waviness on the edge of the part in this photo:

IMG 2066

So I’m ordering some Rage Gold body filler from Amazon (the same stuff I used to make the Tri Delt clamshell prop about five years ago). I’ll do a few layers of filler on the outside so I can cover up the metal edges. But before that I still need to drill out that broken screw (you can see it in that top photo). 

So in spite of the expected (and unexpected) little snags it appears that I have a clear way forward on the shoes! Really happy with the way it’s turning out.

I spent about 3 hours at TechShop this afternoon and in addition to the grinding I also did some thinking about the center leg ankle. The finished part should look like this:

Centerankle5

with this inside (I’ve already made the rectangular part):

PBLCenterFootMount01

 I had what I thought was a shoe-in idea for this and spent some time at TechShop designing a file in Fusion 360 (what a great program), but now that I look at it in the first picture above I’m not so sure it’ll work. More thought needed.

A lot of this thinking is due to the fact that I can’t TIG weld (yet). I really should get off my butt and just do it. I’ll probably ask some advice and start that process next week. So much would be easier about this project if I could just TIG. Even badly. Grinding down that aluminum results in an amazingly clean joint (see the post-ground horseshoe pics above). But the process kind of scares me.

 

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