R2 Greeblies

Here they are; the Ali Greeblies for the R2 outer feet.

Covered with a layer of light grey primer.

Rework

I saw minimal imperfections on the outer foot after a first layer of primer.

So another round of sanding, adding putty to them and again sanding and primering is necessary!

Pic will follow

Primer Day

Today i found some minutes to prepare the three feet for the primer job. 

Sanding was done now and i could paint the light grey primer onto the first two feet!

Bondo Time

I had to add bondo on some spots of the feet, to get a cleaner surface.

Here they are before sanding:

After the sanding job is done, a light grey primer will be painted onto them.

One outer foot

...is done now too!

Now adding some fine putty to some imperfections...

One hour

...of searching for the mistake.

I think i found the issue, why the Ali wire wasn't transported anymore.

There was a fine layer of Ali remains in the structured surface gap of the roll. 

And through the higher pressure of the pressure ball bearing on the other side of the transport system, the wire got flat and caused to get stuck in the transport tube.

I cleaned the roll with a metal brush, cut off the wire that was still in the tubing and took it out.

The pressure roll was again adjusted and the wire was normally running now through the tubing.

Let me see how long it will work...

The last welding spots

...before the welding machine refused to work...

(Sorry for the mess on my working bench)

Another throwback !!

I can't believe it!

First an empty welding gas bottle, then long waiting times for the last ali sheets to be lasercut, additional a lot of work in my enterprise and now problems with the welding machine. Damn'!!

What comes next?!

Yesterday i could bend and weld in the the first channel part (Center foot).

But shortly after that, the welding machine's transport system refused to continue the work. 

 I think i have found the problem. This roll has two small gaps in which the wire is transported.

And if you look closer, there is some fine debris of Ali all around. That comes from the structure of the gaps in the roll. A raw machined surface. Maybe the gaps are worn out? I cleaned the roll, i cleaned the bearing on the other side that is pressing the wire, but until now no success.

Better to order a new roll to get this job done. Meanwhile i will go to the metal Shop where i got the sheets from to ask if they might do the last welding for me.

A big delay

Yesterday i finally could get the last three sheets for the feet.

Now i can finish them!!