Ok, moving on. I didn't get much done today except to confirm what I need to change for the v.2 body frame and acquiring additional material. I got 4 boards of 1/8" MDF at the Home Depot to use for the Shoulder Horseshoes. The Horseshoes are the extra material on the Shoulders, more on that another time. I also got some new router bits at Lowes and a new router at the Wood Craft wood working store. Turns out one of the employees at Wood Craft makes Star Wars costumes. Him and another employee there geeked out when I told them what I was making with the new router.
Once I got back to the shop I took the clamps off the 2nd leg and TaDa! Just a few more details to add and I can start painting.
Before I get rid of it, I tried the aluminum skins on the v.1 body. Good news is it nearly fits. Bad news is I still have to remake it. I also discovered that the body is a tad too short. You can see the skins rising a little higher than the top of the body.
Left side. Flat area cut right but as I said before a rib on each side is not perfectly vertical.
Right side. Is supposed to look like the left side. Oh well.
I also tried the skins with the body template I used to match all the rid slots. It fits perfectly which means I got the diameter correct at 18". Also it appears the vertical ribs are positioned exactly where they need to be.
I'm off this Wednesday so I'll be back in the shop cutting out new pieces for the v.2 body. I might even try to make a template for the Shoulder Horseshoes.