Building the Torso

The Raw Torso
Raw Torso Front View Raw Torso Side View Raw Torso Interior
Front View Side View The Interior
   I purchased this fiberglass torso from Rod Rickenbach. It's right out of the mold, so it needs to be sanded, filled and drilled. This is one part of the robot I absolutely did not want to make myself!
Cutting Holes
Cut Torso Front View Cut Torso Test Fit Cut Torso Test Fit
Openings Cut Test Fit Arms!
   Some progress on the torso, with most of the openings rough cut with a RotoZip and trimmed down with a Dremel tool and a sanding drum. I test fitted the chest lights and arms, just to see what it looked like. :-) The arm holes were cut to 6" instead of the 7" on the plans for better support of the mounting flange for the arms. For hole placement on the chest section, I scanned the relevant sections on a flatbed scanner, then printed them onto removable Laserjet label media. After that, it's just a matter of lining them up, and cutting within the outlines of the holes.
Stacking up the Parts
Parts Stack Parts Stack
   Sooner or later, you get an overpowering urge to see what he's going to look like, so you stack up as many parts as you can. The rectangular slot for the chest buttons has been cut, and the buttons and bezel temporarily fit.
Mounting the Large Chest Lights
Lenses Front View Lens Mount Interior Mount
Lenses from the Front The Frame From the Inside
   I put together a frame to mount Dewey's large chest lenses to the inside of the torso. It's a piece of 3/4" x 1/2" right angle aluminum stock, with two 1" rubber-lined clamps to hold the lenses. Two T3-1/4 lamp holders from Radio Shack have their mounting tabs straightened, and are bolted to the aluminum bracket. The lamps are held in the center of the lens assembly, far enough back so you can put a colored gel behind the white plastic lens. I like this solution because it doesn't require you to glue anything to the inside of the torso: the rubber-lined clamps hold the lenses securely against the surface.

Last updated on Monday, July 28, 2014