Well, today could have been one of those days where the work week got the best of me. After working for 4 hours, driving 5 hours from Kentucky, I got in some work tonight for 5 hours. I am very happy with what I got done. I concentrated on getting the dome into shape.
I started with mounting the holo-projectors, and I have to say the first one kicked my tail quite a bit. I had cut the top section of the inner dome so it would sit flush with the outer dome. Unfortunately, I did this after I had cut out and sized the hole for the holo-projector. This left me little room to mount the screws that will hold the top eye in place. I drilled some holes that were dangerously close to the edge of the opening, mounted the holo-projector and put the top panel inside the dome. It was all well and good until I out the top pie panel on, and it did not sit right. There are little gaps around all of these panels, and the holo-projector was not centered properly which caused the panel to sit crooked.
I tried spinning the inner dome, but then the other openings did not line up properly. This build is a game of millimeters. Everything is made with such tight tolerances, there is no wiggle room in this house. Not 100% sure of what I am doing at any given moment, my trial and error method has served me well. ("Well" meaning I have not botched anything beyond repair).
I drilled a few more holes to reposition the holo-projector and tried again...... and then I did it again. With three sets of holes drilled to mount a single holo-projector, I was rocketing towards F.....rustration-town. Then I got smart, and widened the holes on the holo-projector flange. This offered me enough room to position the holo-projector so the pie panel would sit nice and pretty. (I ended up using the original set of holes to mount the unit - go figure)
Here is a snap of the holo with the pie panel centered in it's groove.
Once this was done, I had to throw the dome on the body for a test fit. Dang - it looks niiiiiiiice.
The aluminum dome mounts to the Rockler lazy-susan bearing via a plastic ring, Below the ring is a large flange that serves as the lower ring closest to the body. This flange is mounted to the plastic ring with counter-sunk screws. This was probably the easiest part of the build so far.
Next up was cutting the panels along the lower rim of the dome to allow the door hinger to be placed inside. First up, marking the cut lines. I learned one thing from cutting the access holes on the top pie panels : Mark where you want to cut, be a man, and cut ON the line. I had tried to cut further away from the line on the top panels, so I could offer myself some play. After all, all you have to do is get a file and remove more material if need be...... Yeah, I have discovered a distinct displeasure with filing aluminum. Too much computer work has made my hands weak. (If it were the summer, I would certainly have my manly fishing hands, but alas, a few scant months of winter and I have the hands that would rival Steinbeck's Curley's mitts.)
Holes drilled to allow access to the Jig Saw. Yeah, I go big. I feel like I actually have more control of the power tool than with a manual hack-saw blade. The aluminum cuts really easy with a bi-metal blade. Taking one's time is a virtue, and I learned that with the top panels.
Side panel done, and holes drilled for the three small doors.
Back on the body for a test fit. It really does not need to be on the body, but it looks very nice when it is. You get a good look at the bottom flange and the plastic ring mounted to the bearing in this shot.
On to the side holo-projectors. I learned my lesson from the first holo mounting process. Test fit, test fit, test fit.....drill. I also marked and drilled these holes from the inside-out - seems only logical. Those who know me, can attest that logic often escapes me at certain times of the day. The holo mounted without a hitch. I also used the captive studs on this mount - they are an absolute joy to work with - and a testament to researching the Astromech boards for tips and tricks from other builders.
There is a little residue from tape on my holo, but I love the etched Builder's Club logo on the back of the unit.
A view form outside.
Gotta have a shot with all three of these mounted !
On to mounting the front logic displays. Tip to builders out there, drill your holes in behind the verticals in between the panels adjacent to the FLD's. Don't try to drill them right next to the bezel, it will make you sad, and you will see the hole(s) behind the cover plate. It only took drilling three holes for me to figure that one out....
A view from the inside.
Next up, the Rear Logic Display. Same process, different size hole. Here is the RLD peeking through the inner dome.
Notice the gap on the right. No worries, I cut the hole with a bit of lateral license. The RLD bezel has mounting holes that allow the unit to be shifter left or right. Nice addition, and most certainly used in this case.
These panels are just laying on the dome. When they are held in place, they look tasty.
Here is the RLD mounted from the inside of the dome. Captive Studs to the rescue once more.
The little unit on the left hand side of the board is a Mini-Arduino. That is the controller for the blinky lights. Just a super-cool piece of technology. I believe the center diamond shaped piece is the processor / memory unit that carries the code to control the 100 or so led lights. Thank goodness for other members who are WAY smarter than I could ever hope to be. This code is available to builders at no cost - share and share alike.
One day, I hope to offer something this valuable to the club in some shape or form... But right now, I am in input mode - gobbling up whatever knowledge other builders have passed down over the years.
So there it is, a nice Friday night session. I glued the top inner dome to the outer dome as I left the workshop - so that will be dry and ready tomorrow. Hoping to have the dome complete and ready for a fully powered, fully lighted spin-tastic test run tomorrow.
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