Scavenger Aluminum Astromech Legs CS:R

[Marc ph]

Scavenger Aluminum Astromech Legs Rev 2.0 CS:R

Difficulty Level: Intermediate




Note: Rev 2.0 has the coupler lock these have been included to prevent the couples from spinning when removing the ankle.

Assembly Guide

Scavenger Legs 1.0 Assembly Guide v2025-June-28.pdf

(1.28 MiB) Downloaded 267 times

Build OF Materials

Scavenger Legs 1.0 Bill of Materials - v2025-June-28.pdf

(126.82 KiB) Downloaded 328 times

Files can be found here for a small donation to charity. Subscription grants access to all files or you can choose one time purchase for $10
https://www.patreon.com/c/ScavengerWorkshop

File 1 of 1
5052 H32 Aluminum (.187")
44.206 x 23.037 in
3_16_scavlegs_v2.dxf






Parts List

Material List (Buy a few extra we use similar parts for other kits)
Quantity 12 https://www.mcmaster.com/91263A889
Quantity 12 https://www.mcmaster.com/90592A016
Quantity 26 https://www.mcmaster.com/90009A221
Quantity 26 https://www.mcmaster.com/91263A837
Quantity 26 https://www.mcmaster.com/91263A841
Quantity 8 https://www.mcmaster.com/90078A210 used as spacer probably cheaper options but looks cool.
Quantity 8 https://www.mcmaster.com/90585A537
Quantity 8 https://www.mcmaster.com/90264A435
Quantity 8 https://www.mcmaster.com/92125A242
Quantity 8 https://www.mcmaster.com/94645A205


Do not Powder coat these legs the heat will remove the adhesive and you will see lines.

Cutting the groove in the leg is simple if you have this tool.

3_16_scavlegs.zip

(39.99 KiB) Not downloaded yet

[Marc ph]

Prep Work

Before you start you will need the tools pictured below.

Make sure you sand all parts with 80 grit sand paper this will allow the metal glue to cure solid.

Glue the inner plates together with the metal glue make sure the plates are perfectly aligned and clamp together with the c-clamps. Allow to cure for 24 hours you will use this same glue for all seams as you are assembling parts.
Metal Repair Glue

After 24 Hours you want to sand and fill this area. This is why we did not want to glue it to the Master rear plate yet it makes it easier to get to this area.

Step 1. Countersink the holes on the two main plates with the Diagram below and the two ladder plates as shown in the photo. Make sure you go slow for each hole testing periodically with the hex screw. Making sure the screw sites just under the surface. you will need to skim some of the screws with filler later to make them unseen.

90 Degree countersink bit

Step 2. with the M6 12mm small hex screws loosely fit all of the couplers on the lower plate once you have dry fit everything you will permanently attach the couplers to the lower plate with Loctite permanent thread lock. Using the stacked horseshoe make sure the couplers are in the correct position before you tighten all bolts

Loctite Thread lock

Step 3. dry fit the ladder you may need to file some of the tabs a bit to get it to assemble once it fits well together using the glue and M6 12mm bolts and nuts assemble the ladder. Once again make sure the bolts rest below the surface you will skim these bolts later with filler and paint over them Loctite is a must here as well

Step 4. At this point you can glue your ladder and stacked plates to the bottom Master plate use a rubber mallet to gently tap the pieces in place. Do not glue the top plate unless you are certain you do not need to run wire or make any adjustments.

Step 5. Mount the shoulder hub mount make sure to adjust the Hight for the hub you plan on using. You may have to cut the tabs to use the bigger hole.

Step 6. Finally bolt glue the top plate in place and Loctite the remaining M6 30mm screws after the glue cures for 24 hours you may prep your part for paint and fill all seams and bolts Most of the bolts will be hidden by greebles.