What the R2D2 Senna Frame Uprights Look Like

Here are the uprights from the R2D2 Senna Wood Frame.  In this picture, they are marked to show what rings will go where.

Frame Uprights
Frame Uprights from the side

Here they are again, stacked up. I made one long template from some 1/2″ MDF and used that to make all the others so all slots lined up perfectly.l

Stacked uprights
Stacked uprights

The R2D2 Wood Senna Frame Part III

The next video is basically the same as the other, except I am cutting out the base plates and sections for the body detail

Its a good idea to mark what side is the top.

Template marked TOP
Top frame template marked TOP

Use the double sided tape to attach and route out.

Top plate template
Top plate template with doublesided tape

The rest is as before.  Set your depths with the router as described in the previous post. Route out and check the fit with the Side Plates and Uprights.

The R2D2 Wood Senna Frame Part II

The following video is just to be used as a rough guide.  I have since figured out a better way to make all the cuts into templates rather than draw them all out.

Use the middle ring template as a way to cut the slots for the shoulder wings, quarter wings, and 1/8th rings.  This will also work for the curve to make sure it is exactly the same.

Rings and Wings
Quarter rings, Eighth rings and Shoulder Wings.

All of these were cut from the middle ring.  I used the middle ring as a guide and it gave me perfect dimensions for all rings to be cut.  The same can be done for the shoulder wings front portions with the slots.  If you make a center line on your bottom plate, you can use that to draw the basic shape of the shoulder wings, including the portion that goes into the the side plates.

Below shows how I cut around a slot I do not want cut into the wood.  A simple piece of wood across the slot will work as long as the bearing on the bit is raised to that point.  Do not go all the way around like this or you will mess up your template and the work piece at the same time.  See this at 3:55 into the above video.

Stick blocks cutting
Stick to go around unwanted cuts

Cutting the slots for the side plates is not to difficult.  Use your jig and set the router properly.

Router bit on work piece
Router bit on work piece

Lower the router onto the work piece and lock in place.

Depth turret turned and rod zeroed
Turret turned and rod zeroed out

Turn the Depth Turret until the Depth Rod hits the lowest point, with the router still plunged into the workpiece.  Lock the depth rod with the lever.  Move the red mark to “0”.

Lock depth rod
Lock depth rod at desired height

Unlock the Depth Rod, and pull up on the rod until the red line is at your desired depth of cut and relock the depth rod.  Now make your cuts.