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1-by-1-by-1/16-inch angle stock 57/64-by-9/16-by-1/16-inch channel stock 41/64-by-1/2-by-1/16-inch channel stock Bar stock, in widths from 1 to 3 inches and thicknesses of 1/16 to 1/4 inch
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You ve no doubt seen those shelving products where you nail two metal rails on the wall and then attach brackets and shelves to them. The rails are referred to as standards, and in a pinch they are well suited to be girders in robot frames. The standards come in either aluminum or steel and measure 41/64 by 1/2 by 1/16 inch. The steel stock is cheaper but considerably heavier, a disadvantage you will want to carefully consider. Limit its use to structural points in your robot that need extra strength. Another disadvantage of using shelving standards instead of extruded aluminum are all the holes and slots you ll find on the standards. The holes are for mounting the standards to a wall; the slots are for attaching shelving brackets. Both can be troublesome when you are drilling the metal for bolt holes. The drill can slip into a hole or slot, and as a result the hole may not end up where you want it. For this reason, use extruded aluminum pieces when possible. It will yield more professional results.
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Galvanized mending plates are designed to strengthen the joint of two or more pieces of lumber. Most of these plates come preformed in all sorts of weird shapes and so are pretty much unusable for building robots. But flat plates are available in several widths and lengths. You can use the plates as is or cut them to size. The plates are made of galvanized iron and have numerous pre-drilled holes in them to help you hammer in nails. The material is soft enough so you can drill new holes, but if you do so only use sharp drill bits. Mending plates are available in lengths of about 4, 6, and 12 inches. Widths are not as standardized, but 2, 4, 6, and 12 inches seem common. You can usually find mending plates near the rain gutter and roofing section in the hardware store. Note that mending plates are heavy, so don t use them for small, lightweight robot designs. Reserve them for mediumto large-sized robots where the plate can provide added structural support and strength.
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Most hardware stores carry a limited quantity of short extruded steel or zinc rods and squares. These are solid and somewhat heavy items and are perfect for use in some advanced projects, such as robotic arms. Lengths are typically limited to 12 or 24 inches, and thicknesses range from 1/16 to about 1/2 inch.
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You will need a way to connect all your metal pieces together. The easiest method is to use galvanized iron brackets. These come in a variety of sizes and shapes and have predrilled holes to facilitate construction. The 3/8-inch-wide brackets fit easily into the two sizes of channel stock mentioned at the beginning of the chapter: 57/64 by 9/16 by 1/16 inch and 41/64 by 1/2 by 1/16 inch. You need only drill a corresponding hole in the channel stock and attach the pieces together with nuts and bolts. The result is a very sturdy and cleanlooking frame. You ll find the flat corner angle iron, corner angle ( L ), and flat mending iron to be particularly useful.
Working with Metal
If you have the right tools, working with metal is only slightly harder than working with wood or plastic. You ll have better-that-average results if you always use sharpened, wellmade tools. Dull, bargain-basement tools can t effectively cut through aluminum or steel stock. Instead of the tool doing most of the work, you do.
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