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10.1.5 FINISHING
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Cutting and drilling often leave rough edges, called flashing, in the metal. These edges must be filed down using a medium- or fine-pitch metal file, or else the pieces won t fit together properly. A rotary tool with a carbide wheel will make short work of the flashing. Aluminum flash comes off quickly and easily; you need to work a little harder when removing the flash in steel or zinc stock.
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10.2 Building the Buggybot
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The Buggybot is a small robot built from a single 6-by-12-in sheet of 1 16-in-thick aluminum, nuts, and bolts, and a few other odds and ends. You can use the Buggybot as the foundation and running gear for a very sophisticated petlike robot. As with the robots built with plastic and wood we discussed in the previous two chapters, the basic design of the all-metal Buggybot can be enhanced just about any way you see fit. This chapter details the construction of the framework, locomotion, and power systems for a wired remote control robot. Future chapters will focus on adding more sophisticated features, such as wireless remote control, automatic navigation, and collision avoidance and detection. Refer to Table 10-1 for a list of the parts needed to build the Buggybot.
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METAL PLATFORMS
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TABLE 10-1 Parts List for Buggybot (see parts list in Table 8-4 of 8 for motor control switch) 1 2 2 2 2 1 1 Misc. 6-by-12-in sheet of 1 16-in-thick aluminum for the frame Tamiya high-power gearbox motors (from kit see text) 3-in-diameter Lite Flight foam wheels
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56 nuts (should be included with the motors) 16-in collars with setscrews
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Two-cell D battery holder 11 2-in swivel caster misc 1-in-by-6 32 stove bolts, nuts, flat washers, 1 2-in-by-6 32 stove bolts, nuts, tooth lock washers, flat washers (as spacers)
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10.2.1 FRAMEWORK
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Build the frame of the Buggybot from a single sheet of 1 16-in-thick aluminum sheet. This sheet, measuring 6 by 12 in, is commonly found at hobby stores. As this is a standard size, there s no need to cut it. Follow the drill-cutting template shown in Fig. 10-2. After drilling, use a large shop vise or woodblock to bend the aluminum sheet as shown in Fig. 10-3. Accuracy is not all that important. The angled bends are provided to give the Buggybot its unique appearance.
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10.2.2 MOTORS AND MOTOR MOUNT
The prototype Buggybot uses two high-power gearbox motor kits from Tamiya, which are available at many hobby stores (as well as Internet sites, such as TowerHobbies.com). These motors come with their own gearbox; choose the 1:64.8 gear ratio. An assembled motor is shown in Fig. 10-4. Note that the output shaft of the motor can be made to protrude a variable distance from the body of the motor. Secure the shaft (using the Allen setscrew that is included) so that only a small portion of the opposite end of the shaft sticks out of the gearbox on the other side, as shown in Fig. 10-4. You should secure the gearboxes and motors to the aluminum frame of the Buggybot as depicted in Fig. 10-5. Use 6 32 bolts, flat washers, and nuts. Be sure that the motors are aligned as shown in the drawing. Note that the shaft of each motor protrudes from the side of the Buggybot. Fig. 10-6 illustrates how to attach the wheels to the shafts of the motors. The wheels used in the prototype were 3-in-diameter foam Lite Flight tires, commonly available at hobby stores. Secure the wheels in place by first threading a 3 16-in collar (available at hobby stores) over the shaft of the motor. Tighten the collar in place using its Allen setscrew. Then cinch the wheel onto the shaft by tightening a 5 56 threaded nut to the end of the motor shaft (the nut should be included with the gearbox motor kit). Be sure to tighten down on the nut so the wheel won t slip.
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