A few days later of reading..........Wood Frame Construction

After a few days of studying the Yahoo R2D2 Builders Club files / photos/ Blueprints and subscribing to their mail ,  I have downloaded some CAD Drawings and PDF's. The primary drawings here taking my interest are the 'Senna Wood Frame Plans', Named after the Builder who designed this particular framework suitable for wood, I take the drawings into my work to see if they will let me print them off at 1:1 scale. I should point out that during the days it took me to absorb so much information, I had the choice of going down the expensive 'Full Aluminium ' Build, which would take a lot lot longer and a lot more cash, as these parts and frames are usually produced in 'Part Runs' and you can be waiting months for the part, and also , most of the production of these parts are made in the USA, so the cost of the part, the postage, and the unwelcome 'Import Tax' usually makes these items far too expensive, and so I decide that I want to build a budget price full scale R2D2.  So, wood it is. I also decide that my R2 will be a static model, that i have no intention of having it move under Radio Control, just a couple of lights and I will be happy. Its funny how things change in time, but more of that later.
Back at work, and the kind folk I work with, after humoring me a little , print off the Senna frame templates, which I take home, and after a visit to the local DIY show, glue the templates onto some Plywood, of varying thicknesses, but 12mm springs to mind. If you decide to glue paper to wood to allow you to cut around the template - used wallpaper paste and let it dry. It makes it so much easier to remove the paper later on !

Now after a couple of evenings, I have all the parts for the frame. But its clear that if I want this to be glued and screwed properly then I cant rush it, hence only a few bits per night should be attempted to be stuck into place. Also I found out that the two main body uprights, that will later support the hubs of the legs, unless these are exactly 90 degrees, and parallel to each other, they will later throw the legs out of line - so pay close attention at that stage. Heres a couple of pictures of the frame being assembled.

I did all the cutting with a cheap Jig-a-saw, which was not much cop. I also managed to get trough a packet of blades, and also employed the use of a router. Not something I had done before, but a bit scary at first. Please use proper eye & respiratory protection, as the dust still gives your throat the feeling of sandpaper, your eyes sore, and the smell of cut / and burnt wood lingers on you until your showered ! Its also noisy, so protect those lug-holes ! Don't worry if the fit of the wood is a little loose and gappy, with the use of the forgiving wood filler and a band sander or regular sand paper, you can tidy up many mistakes. So - you have something that looks similar to the above? 
Its at this point I present my frame to my mother, with the customary 'Ta-daaaa!!!!' To which her reply is ' why are you building a coffee table?'  Off to another great start !
Looking back - I would recommend looking through the images section of the Yahoo Club and Astromech.net files for photos of the other club members frames, seeing is believing, and helps with the jigsaw puzzle that will later be R2's Body.