The frame already has skin mounting blocks installed with pre-drilled holes. The next step is to carefully drill holes into the skin that line up with them.
So how do you do that?
Well, last year at our New England R2-D2 Builders Club BBQ, Ethan Aho showed me a very clever tool for doing just that. Its called a threaded-hole transfer punch. You thread it into the hole with the provided tool. The end has a sharp tip to it, so when you line up the skin and tap it with a rubber mallet, it leaves a mark....
With the skin sporting the marking "dimples", I used a 1/8 inch drill bit and drilled the holes. And, as I have done with the other R2, I used hex-head 4-40 screws to mount it in place.
And here's how it looks with the doors/panels open and closed...
