When I was assembling R6 at Celebration V, I discovered the bolts which hold the ankles to the feet wouldn't fit through the holes in the feet. The bolts were the correct size, but the holes were just a bit small. So yesterday I fixed that by using my Dremel with a small sanding drum to widen the holes a bit. Now the bolts will fit so the legs and feet can be securely connected.
While I was at the shop I started working on a new head for R6. The main problem with the current one is the crown, or lack there of. I had thought I could add it on later but my attempts to do so have fallen short in good results. So my new design for the head will be to made the vertical ribs one whole piece, including the crown. I'll be making 6 ribs (fewer than the current head has) mounted to a base that will sit on the rockler bearing. My first attempt at making the first rib leaves some room for improvement but with a few adjustments it should work this way. Once assembled I will continue as originally planned and wrap the head with styrene or sintra (both are similar types of PVC based plastic). Can I get all that done before Droid-Con? Maybe, but I'm more eager to get the foot drive system finished first.
Speaking of the foot drive, I ordered the aluminum tubing and it should be here any day. Maybe Sunday I can start on that.