The piece on the bottom of R2’s body that goes around the center leg is called the skirt. This turned out to be a pretty tricky part to make. I started by making the bottom plate of the skirt from 3/4” Plywood. Here you can see the layout:
The flat side of the plate was cut on the table saw.
The rounded ends were made using the same technique I used to make the body plates. I rough cut them on the bandsaw and them cleaned up the cut using my router table jig.
To cut out the inside, I started by drilling holes in the four corners.
I cut the long edges on the router table, putting the flat side up against the fence and cut the other sides free hand using a jig saw.
