Kevin Roche (kproche) wrote,
Kevin Roche
kproche

Catching Up -- Jan 13: ball joint cages and saddle

I'm way behind on this journal, but I'm going to break up the work into chunks to save your sanity.



First I built the cages for the ball joints and mounted my bicycle seat.
The carrier layer (hole as big as the ball, as opposed to the retainer plates cut out of wood) of the cages is Delrin donated to me by the shop at work.



Eyestalk bracket and ball joint plates stacked and drilled
Eyestalk bracket and ball joint plates stacked and drilled
Stack of parts for one ball joint, ready for drilling on a drill press
Stack of parts for one ball joint, ready for drilling on a drill press
stack of ball joint frame parts
The 3" hole in the gun box forms the final component
stack of ball joint frame parts
Parts for ball joint frame: inner (bolt holding) carrier, outer carrier, outer keeper
The carriers have 3.25" holes in them to let the ball turn freely, the keeper has a chamfered 3.00 inch hole to keep the ball in place
Parts for ball joint frame: inner (bolt holding) carrier, outer carrier, outer keeper
Inner carrier with carriage bolts in place
This will screw to the inside of the gun box, trapping the bolt heads
Inner carrier with carriage bolts in place
Tiki Dalek, project tdk, gallifrey one, doctor who, costume, conventions, silliness
closeup of outer plate, aligned to be screwed in place to the gun box. The ball was there to double check the alignment
Tiki Dalek, project tdk, gallifrey one, doctor who, costume, conventions, silliness
positioning pin to align the carrier plate.
I drilled 8 holes for each plate, then flipped it and put screws through from the outside
positioning pin to align the carrier plate.
Carrier plate clamped in place to place screws
Carrier plate clamped in place to place screws
Carrier plate attached to inside of gun box, inside view
Carrier plate attached to inside of gun box, inside view
Carrier plate screwed in to inner face of gun box
Carrier plate screwed in to inner face of gun box
Completed gun box (with ball joint inner assemblies screwed in place)
Completed gun box (with ball joint inner assemblies screwed in place)
Inside view of assembled ball joints
Inside view of assembled ball joints
Closeup of assembled plunger arm ball joint
Closeup of assembled plunger arm ball joint
Closeup of assemlbed gun ball joint
Closeup of assemlbed gun ball joint
Assembled gun box with torch gun and plunger arm
Assembled gun box with torch gun and plunger arm
post for bicycle seat
That's a 1/2" pipe threaded into a floor flange. The saddle will just clamp on to the pipe
post for bicycle seat
Bicycle seat mounted to cross-strut
Bicycle seat mounted to cross-strut


Tags: conventions, costume, doctor who, project tdk, silliness, tiki dalek
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