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There are a number of other tools you can use to make your time in the robot shop more productive and less time consuming. A drill press helps you drill better holes because you have more control over the angle and depth of each hole. Be sure to use a drill press vise to hold the pieces. Never use your hands! A table saw or circular saw makes it easier to cut through large pieces of wood and plastic. To ensure a straight cut, use a guide fence or fashion one out of wood and clamps. Be sure to use a fine-tooth saw blade if you are cutting through plastic. Using a saw designed for general woodcutting will cause the plastic to shatter. A motorized hobby tool, such as the model shown in Fig. 3.1, is much like a handheld router. The bit spins very fast (25,000 rpm and up), and you can attach a variety of wood, plastic, and metal working bits to it. The better hobby tools, such as those made by Dremel and Weller, have adjustable speed controls. Use the right bit for the job. For example, don t use a wood rasp bit with metal or plastic because the flutes of the rasp will too easily fill with metal and plastic debris. A RotoZip tool (that s its trade name) is a larger, more powerful version of a hobby tool. It spins at 30,000 rpm and uses a special cutting bit it looks like a drill bit, but it works like a saw. The RotoZip is commonly used by drywall installers, but it can be used to cut through most any material you d use for a robot (exception: heavy-gauge steel). Hot-melt glue guns are available at most hardware and hobby stores and come in a variety of sizes. The gun heats up glue from a stick; press the trigger and the glue oozes out the tip. The benefit of hot-melt glue is that it sets very fast usually under a minute. You can buy glue sticks for normal- or low-temperature guns. I prefer the normal-temperature sticks and guns as the glue seems to hold better. Exercise caution when using a hot-melt glue gun: the glue is hot, after all! You ll know what I m talking about when a glob of glue falls on your leg. Use a gun with an appropriate stand; this keeps the melting glue near the tip and helps protect you from wayward streams of hot glue. A nibbling tool is a fairly inexpensive accessory (under $20) that lets you nibble small chunks from metal and plastic pieces. The maximum thickness depends on the bite of the tool, but it s generally about 1/16 inch. Use the tool to cut channels and enlarge holes. A tap and die set lets you thread holes and shafts to accept standard-sized nuts and bolts. Buy a good set. A cheap assortment is more trouble than it s worth.
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FIGURE 3.1 A motorized hobby tool is ideal for drilling, sanding, and shaping small parts.
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A thread size gauge, made of stainless steel, may be expensive, but it helps you determine the size of any standard SAE or metric bolt. It s a great accessory for tapping and dieing. Most gauges can be used when you are chopping threads off bolts with a hacksaw. They will provide a cleaner cut. A brazing tool or small welder lets you spot-weld two metal pieces together. These tools are designed for small pieces only. They don t provide enough heat to adequately weld pieces larger than a few inches in size. Be sure that extra fuel and oxygen cylinders or pellets are readily available for the brazer or welder you buy. There s nothing worse than spending $30 to $40 for a home welding set, only to discover that supplies are not available for it. Be sure to read the instructions that accompany the welder and observe all precautions.
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