Data Panel Servo Replacement Kit

I built a project earlier to place a servo for the Data Panel Door in Mr. Baddeley's R2-D2 design. You can see it here as it is the basis of this project: https://www.thingiverse.com/thing:2980988. The original project was designed to be installed before rings one and two were attached. If you have already attached those rings (or need to replace the servo as I did), these pieces will help you.

Since the axle needs to be assembled inside the body and you cannot see what you are doing to put the arms on, I built two jigs to help align the arms which are mounted to the top and bottom of the axle. Basically, you will need to put the top arm on the axle. Then, use the axle sleeve to get the proper rotation of the assembly to line up with the bottom arm. Here comes the hard part. You slide the lower arm into the Jig and wiggle it around until it sits flush under the axle. Then, using a flathead screwdriver push from the top until the bottom arm slips onto the axle. (Please fit test this beforehand to make sure it is a snug press fit.)

Once you have the upper and lower arms attached to the axle, remove the axle sleeve as it prevents the assemble from turning. The next step is to mount the servo and attach the arm sleeve with a small stiff wire (such as a portion of a paperclip). OK, now is the second hard part. You have to slide the mount into its spot on the droid while sliding the sleeve onto the lower arm. Once you accomplish this minor feat, you secure the servo mount with three screws and the arm sleeve with one small screw.

I built a little test jig to help me get the servo set up and get the right swing of the axle. You can see that in the photos. These files are the servo mount test and axlestand.