Hello everyone. My CO Damien has a Laser Cutter in his garage... so I paid him a few dollars to take the wizardofflight templates and to punch them in. One failure later, we finally got the scaling correctly! Something funny happened in the file transfer, hah; they needed to be converted to be compatable.
If you look closely in this photo, (top left of photo) you will see a bunch of laser cut pieces, the knees being part of them. I had him cut the pieces for my rocket on the jet pack, you can look at my other thread for that. If you see the pieces for the knee, you'll see that they were at one point flat .
At Comic Con, I ended up to lose my digital camera. Boba Fett missed his thigh pouch as he was putting his camera away. So you guys get webcam pictures... they are okay, but you get the point. Since I didn't have a camera, the knees are about 80% completed as I start to put pictures on the site. Once I finally decided to work on the knees, it took about 3 days to get to where I am now, would have been 2 if I didn't run out of Super Glue .
Step 1: Politely ask wizardofflight for his knee templates in CAD format.
Step 2: Laser cut the drawings.
Step 3: Boil some water and mould them into the correct shape.
Step 4: Super Glue together all of the parts.
Step 5: Bondo all of the seams.
Step 6: Cut out chunks of wood for the part that houses the darts.
Step 7: Screw them in.