Some ideas are good ones. Some not so good.
I spend some time with the body tubes projecting out the lines from the armatures that need to be cut away to fit the tubes to the rectangle. Reading how others have done this and being lazy i started by using the aforementioned 17-4 block and painting guide lines onto the body tubes. This worked meaning in the loosest terms in that i got lines on the tubes. Something told me it was not going to work though.
The good idea therefor was to make extra body tubes. You can probably figure out now the bad idea...
All eight tubes were "painted" up oh so many ways this can go south.
- Are the tubes aligned to the armature?
- Are the tubes aligned to each other?
- Did you get the 17-4 block perpendicular?
- Did you get overspray?
- Did you use any other paint color but grey on the grey tubes so you have contrast?
If your keeping score the answers are: No, No, No, Yes and Nope...
So pretty below but fate had other plans.
I did not get any good images but the paint was a complete failure. (In case you missed that foreshadowing...)
I jumped to good-old-fassioned tape. Using my Mark-1 eyeball i projected out with tape where the lines should be. If your keeping score then you will see that all the same risks apply here other than over spray.
Did i mention i am lazy? If i only had a tool that cuts straight lines relative to how the part is held... Hey, i have one of those...
I was smart enough to realize things could still go sideways. I put each tube in the mill and machined a rectangle along the blue tape line leaving 1/16" gap for fitting. (Plus i had to hand file the corners square.) This was a wise move because i got nice parallel and perpendicular lines and was then able to hand file and hand fit each tube then to its armature. (Don't mix them up dummy...) I was able to hit the for/aft width on the money relative to the armature tube but the up/down was difficult.
My results and what i learned was.
- Tubes get wonky leading to you sanding one side of the square over the other leading to tilted tubes.
- Tape messes up the squareness of your cut leading to rotated tubes along the body axis.
- Tape also messes you up along the armature axis leading to converging tubes.
- The faster you can cut things out means the faster you make mistakes.
Got every combination but in the end two of them are good and two are.... well i have two good armatures still.... You can see clearly in the bottom one of this image how the tubes are wonky. They can be "fixed" but your start getting large gaps at the armature.
A collection of parts, some part maps and Lord Vader for inspiration. (That is the stock Vader kit my son & I built some years back. His first model.)
All good adventure have chapters that don't go as expected. I am certain this was the last sideways skew for this project. Ya right....