If you have taken apart or cast an R2 and need a good way to put the legs back on here is my method. This method is for a regular POTF2 R2 with the middle leg removed. The process with a little modification will probably work on R5 or the other versions of R2.

I used a #6 sheet metal screw to attach the legs because the head of the screw was the correct diameter to fit inside R2's leg. I'm not sure how much screw head diameters change by manufacturer but find one the fits to you liking.

Step 1

Take the back half of the body and cut off the rivet like knobs that the legs were attached to.

Step 2

Now carve out the half circle, left by the cutting of the post, to match the half circle already in the front of the droid (Here a Dremel is recommended).

Step 3

Take one of the legs and a #6 x 1/2" sheet metal screw. Put the screw through the axle hole in the leg and put a #6 flat washer on top of that.

Step 4

Next take the 1" piece of 3/16" tubing and screw the leg assembly onto it.

Step 5

Repeat the process for the other side. DO NOT OVER TIGHTEN! or you will strip out the plastic tube. The completed leg assembly should fit right in the two half circles.

Step 6

Before putting the droid together you must sand about 1/16" from the bottom of the head so it does not interfere with the 3/16" axle tube.

Step 7

Glue the Astromech halves back together and don’t forget to put the head back on. Be careful not to get glue on the new axle or in the groove where the head swivels if you want the droid to be articulated.

Step 8

After the glue has dried, using two screwdrivers, tighten the legs to a desired fit.

You can leave the leg assembly off when you glue the two halves together to make painting easier. Then assemble one side of the leg assembly slide it through the droid then screw on the other half.

REMEMBER to Dry Fit all assemblies before you glue to make sure of a proper fit.