AssemblyInstructions¶
Temporary location for assembly instructions
Chassis Assembly Preparation¶
- Cut sheet metal parts
- File sharp edges, countersink all holes (from correct side)
- Bend to spec, validate with bend check tools CRITICAL
- Sandblast and clean
- Powdercoat or primer and paint (use Rustoleum Satin Finish), enamel clearcoat (satin)
Chassis Assembly, Front Half¶
- Install Pivot block
- Using #4-40 CSK hardware, tighten pivot block into position
- Ensure perpendicularity with long axis of robot (otherwise robot halves will collide and robot will not drive straight)
- Install return springs
- Slide spring onto bent tab, ensuring parallelism with vertical plane
- Install wire retainer from (outside) of front half, aka space between the halves
- Twist the retaining wire tightly over the spring, clip neatly
- Front Cliff Sensor
- Solder wires according to wiring diagram (link?)
- Install on front mounting tab using #2-56 SHCS, lock washer, and nut, or nylock
- Be careful not to distort mounting tab
- Front Drivetrain
- Solder capacitor and attach wires according to wiring diagram
- Solder 0.1" pitch vertical standoffs (4pins each) to encoder pcb
- Using long #2-56 screws and provided nuts (in motor bracket), install spacer plate, encoder pcb, motor, and motor bracket.
- Wheels can remain off for time-being, or can optionally be installed.
- Install Air Filters on Side Panels
- Adhere (6) custom bent polypropylene clips following placement guide (link?) to side panels
- Use XXXX epoxy, taking care to use only the amount necessary. Do NOT touch other parts of the panels as this will mar the paint job
- After epoxy is dried, custom cut air filter panels can be slid into place. They should be constrained on three sides (left, right, bottom).
- Ensure no visible gaps from outside of front assembly.
- NOTE: This step can be done in parallel with parts 1-4
- Front undercarriage plate
- Affix diamond plate film to plate, covering entire exposed surface
- Trim neatly with a SHARP razor blade, ensure no visible snags are present
- Loosen the two frontmost motor bolts (#2-56) and slide the front undercarriage plate under these bolt heads).
- Use of washers is recommended if bolt length still protrudes past nuts in motor brackets
- Re-tighten bolts. The front undercarriage should now be secure
- Side panel/Scoutfly mounting blocks
- Using 1 front right side (long) 1 front left side (short), and 2 front vertical mounting blocks
- Thread all to accept #2-56 hardware WITH THE EXCEPTION of the ciruit board mounting holes, which require #4-40 SHCS hardware
- Secure appropriate parts to front undercarriage and baseplate
- Install Side panels
- Side panels with installed air filters can now be bolted into mounting blocks using #2-56 CSK hardware.
- One bolt on left side will be nutted into place (nylock) as the short mounting block does not reach this hole
- Shortened for Scoutfly underside connector clearance - Nut this bolt in place to plug hole for aesthetics and intrusion prevention (dust, water, etc).
- Hood Assembly
- Bolt hinge strut in place on side of hood using #2-56 CSK hardware. Bolts should NOT protrude beneath strut
- Bolt rear air filter to strut using #2-56 CSK hardware.
- Heat and bend front headlight assemblies according to spec. Should have 1 left and 1 right side bent from same cutout
- Apply pre-cut diamond to inside of each headlight cover as per spec sheet (link?)
- Apply adhesive (cyanoacrylate/super glue) around perimeter of headlight that will be in contact with hood
- CRITICAL: do not apply extra glue or smear on visible portion of headlight assembly. More can be added later once headlight cover is in place
- Align (center) over headlight cutout, ensuring bolting hole is aligned. Press into place and hold for 30+ seconds.
- More adhesive (clear epxoy) can carefully be applied around perimeter to ensure solid contact. This will be important since headlight assembly is part of hood clasp
- Install front BOM components and tactile switch into mounting block
- Using epoxy and #2-56 CSK hardware to attach front BOM/bumper switch mounting block. Again ensure epoxy is not visible on exterior, and has a clean look inside
- The hood is perhaps the most visible component, and both inside and outside will be viewed frequently, so take the time to do a nice job on this.
- Install Hood on Front Half
- Bolt hood to side panels using #2-56 CSK hardware. Remember this is a moving hinge, so do not over-tighten.
- If installed properly the rear air filter should "seal" off the rear hatch when the lid is closed.
- Once Scoutfly and grounding strap are mounted, magnet clasp assembly will be installed.
- Grounding strap
- Prepare grounding strap with (2) ring terminals per wiring diagram
- Attach one end to front pivot block using #4-40 SHCS hardware