I printed an ABS template for the bolt pattern (Legs, through Shoulder Flanges to Frame) which I used to transfer the center points for the bolts which are evenly spaced on a 5” radius. The Legs were drilled out on the Drill Press, using some jigging to keep things square and true. The bolt holes were counter-sunk on the outside surface. I also used a 2.5” Hole Saw and my Plunge Router for the clearance hole for the Shoulder Hubs, which should really have been done before the glue-up of the pieces.
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Well, I'm well on my way with this build and now I have finished construction of my CNC machine (router & large 3D Print Bed). After calibrating and some testing, my first meaningful project with it was to cut a full set of Birch pieces for another pair of Legs and Center Ankle. This worked beautifully. I was more than happy with the results and seriously considered (for a moment) abandoning the R6 Legs that I had started. However, I was far enough along that I had to see the first set completed… I couldn’t waste the time I had already put into them. The new pieces will be a good start on my next Astromech! (To be honest, my Hand Cut layers were every bit as good and accurate as the CNC cut ones… the only thing I missed was the ability to pre-drill accurate holes)