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Now that our leg assembly is built,
we will need to add a clevis mount
to the bottom of the rear brace as
shown in the photo above. To
achieve this I cut the top off of a
1" X 2" piece of tube steel and
then chop off 1" of the larger
bottom section. I rounded the top
edges and then drilled a 1/2" hole
through both pieces now
sticking
up to hold the 1 1/2" piece of 1/2"
solid steel rod I will be attaching
my air cylinder to. In this photo on the
right you can also see two 1/4"
holes drilled in the bottom of the
U, and squared off, allowing us to
attach this to the leg brace with 1
1/2" x 1/4" carriage
bolts.
Now we make our connector pin for
the air cylinder from the steel rod and
drill a 1/4" hole in the center and
then more hitch pin holes on each
end as we did for the knee axles.
Once again, space them to fit snug
to the clevis with one washer on
each side to minimize wear as the
pin pivots in the mount. Mount this
on center to the brace.
Next we turn to the mounting
bracket for the skeleton so we have
a place to put our leg assembly. I
started with a 2" X 4" piece
of steel tube that I cut to 4" long.
Next I made one cut lengthwise on
both sides, revealing two identical
mounts that are 2 3/4" tall each. I
recommend de-burring all of your
steel pieces as you go for safety. Now clamp these two
pieces back to back to make sure
your hole will be perfectly level
and measure 2 3/4" up from the
bottom to drill your 1/2" pivot rod
hole on center to the bracket.
Finish your brackets by drilling
two 5 /16" holes through the bottom
so they can be bolted to the top of
the seat box. Now cut a 14 1/4"
length of 1/2" solid steel rod to
slide through the bracket, then
through a 1/2" flat
washer,
then the leg and over to the other
leg and bracket. Shown here are
some collars I am using on the ends
of the rod to keep it nice and
snug against the brackets to
prevent side to side movement.
Hitch pins could have worked here
as well, but the ease of using the
collars appealed to me. Next we
need to get this attached to the
chair seat so we can get on to the
torso of our condemned creep.
This animation will be rather
demanding on the chair that we are
bolting him to, so it is important
to insulate the concussion of his
movements from distressing the wood
or the joints. I decided on
mounting him to the chair with
steel springs to absorb this
constant abuse so the chair should
stand up to years of use. At first
I used a lighter weight spring than
shown here in the photo and it
simply didn't do the job, so I
recommend you find a
Century
spring #C-892 or similar. This is a
heavy duty spring that has an
inside diameter of 3/4". This comes
into play in a moment. We will need
to cut off 4 pieces 3/4" long each as shown below. Since our 5
/16" bolts are no where near 3/4"
diameter to keep the springs from
migrating off of the washer we will
be placing between the spring and
the wooden seat surface, we will
need some sort of spacer. I found
that standard 3/8" rubber air hose
was not
only the right size outside, but
would fit snugly around the bolt to keep the springs right
in place. You will need four of
these cut to about 1/2", eight 5 /16" flat washers and four lock
nuts. The bolts are 5 1/16" as
mentioned and 2 1/2" long. Also, something not shown in
the photo above are some rubber
washers that I decided to use for
further insulation of all of the
concussion pieces that would be
mounted to the chair such as the
air rams and of course the
skeleton. Called 5 /16" Tank Bolt
Washers and made fo r your toilet
tank connection, you can find these
in, you guessed it, the plumbing
section of your local hardware
store! These will be placed
underneath the bottom washer below
the spring to keep the steel washer
from coming into contact with the
wood which would eventually wear
through if left in contact. Hopefully with
this layer of belted rubber this
will never be a w ear point on the
chair. Remember to also place one
of the rubber washers between the
flat
washer and the wood underneath the
seat as well. Here is the spring assembly
just before placing the leg
assembly down to complete the
attachment. And here is how
it will look fully assembled.
It is important to note here
that
you will not be tightening the nut
down on the bracket. Just bring the
nut down until it is firmly seated
so you allow the spring to do it's
job to absorb the vibration. No
part of this build I feel is more
important than this connection,
that's why so much time has been
spent in it's discussion here.
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