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...... Legs ......

Used the usual pipe insulation for the legs, but instead of split and wrapped around wooden plates, it is threaded over 1" PVC pipe.

This is an idea copied from Donald G's website "A Slightly Different B9 Robot" - a very good site with lots of ideas, well worth a visit.

Made the first loop from material that was lying around - cheap flexible plastic hose ($8 for 10m), thin walled 1" PVC pipe, and for joiners some sprinkler reticulation tubing with tape wrapped around until it formed a snug fit.

Bent into a loop with more tape over the joins to keep them from coming apart.

Placed on the tread section to check the fit.

With pipe insulation threaded on, the seam will be on the inside of the legs so it wont be noticeable. The pipe insulation can vary in size, if it's a bit tight, some talcum powder is the best lubricant, then it slides on very easily. Happy with the result so time to make some more of varying sizes ...

Worked out what lengths of pipe would be needed to form the top ring near the waist plate, and the bottom rings near the knees, from the club blueprints. Interpolated from that, the values for the rings in-between. Then, because the flexible pipe doesn't start to curve straight away, due to the joining piece, i subtracted about 1cm from the lengths of the rigid pvc pipe and added it to the flexible pipe. After that, just fiddled with any dimensions that didn't look right until had the desired final look.

Lengths of flexible tube and PVC pipe, each set slightly longer than the previous one.

Joined together.

Threaded with pipe insulation.

Bent into a loop and joined.

Seam moved around to inside.

Test stack of the varying sizes to check the appearance. Afterwards these were stuck together with silastic.

Completed legs sprayed with Plasti-Dip that happened to be blue, to be sprayed later with grey vinyl dye. The upper loops are formed from two pieces with the join where the "zipper" will be. Completed legs are quite light, (3.8 kg) and seem to hold their shape, though i used some cable ties across the middle to make sure.

Leg framework made from 25mm square aluminium tube with plastic corner pieces from the local hardware store, surprising how strong and rigid it was when assembled in a box-like structure. Another piece of the flexible tube was used as a conduit for the cables to the batteries and motors in the tread section.

Waist plate sits on top of the framework, the rubber legs support themselves with out any need for a "sub waist plate". Over a few months the height of the legs settled by about an inch, could of prevented that but i like the slightly more squished look. Simply trimmed the height of the aluminium support to suit.
The knee bellows seen here are only temporary until the correct ones from Will Huff arrive. These were actually the test pieces made before the rest of the legs.

After spraying with grey Vinyl dye.

This is the vinyl dye used, it covers remarkable well. One light coat covered up the blue and made it look grey, but gave it a second coat just to be sure. Used the "satin mid grey" there was also a dark grey but from the colour of the cap it looked too dark, this is pretty close to the rubber.

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