| 1 | * attach arduino to deck |
| 2 | - [ ] locate materials |
| 3 | - [ ] 1x arduino |
| 4 | - [ ] 1x deck |
| 5 | - [ ] 4x spacers |
| 6 | - [ ] 4x 6-32x5/8 inch bolt |
| 7 | - [ ] 1x 6-32 nut |
| 8 | - [ ] locate tools |
| 9 | - [ ] safety goggles |
| 10 | - [ ] magnetic tray |
| 11 | - [ ] 5/64 inch hex wrench |
| 12 | - [ ] pliers |
| 13 | - [ ] drill |
| 14 | - [ ] drill bit |
| 15 | - [ ] drill 1 hole, put in 1 bolt |
| 16 | - [ ] drill second hole, furthest away from first hole, put in 2nd bolt |
| 17 | - [ ] drill 2 remaining holes |
| 18 | - [ ] loosen first 2 bolts until arduino comes off |
| 19 | - [ ] put in all 4 bolts just enough to place spacers on them |
| 20 | - [ ] put arduino on top and tighten all but bottom right bolt |
| 21 | - [ ] hold locking nut with pliers, shiny side toward arduino, while |
| 22 | tightening last bolt into it. |
| 23 | * make sonar cables |
| 24 | - [ ] locate materials |
| 25 | - [ ] 2x 220mm red stiff wire, solid core 22 awg |
| 26 | - [ ] 2x 220mm blue stiff wire, solid core 22 awg |
| 27 | - [ ] 2x 220mm yellow stiff wire, solid core 22 awg |
| 28 | - [ ] 2x 220mm black stiff wire, solid core 22 awg |
| 29 | - [ ] 4x zip tie |
| 30 | - [ ] 8x terminal |
| 31 | - [ ] 2x white housing, 4 positions |
| 32 | - [ ] locate tools |
| 33 | - [ ] magnetic tray |
| 34 | - [ ] 1x crimper |
| 35 | - [ ] 1x wire stripper |
| 36 | - [ ] 1x wire cutter (or reuse wire stripper) |
| 37 | - [ ] prepare wires |
| 38 | - [ ] strip 1 end of all 8 wires by about 3mm (3/16 inch). |
| 39 | the terminal will crimp onto this end |
| 40 | - [ ] crimp terminals onto exposed end of wires |
| 41 | - [ ] strip other end of all 8 wires by about 2cm (1/2 inch). |
| 42 | this end will plug into the breadboard or arduino header |
| 43 | - [ ] finish cables |
| 44 | - [ ] put crimped ends into housing in the order: |
| 45 | black, yellow, blue, red |
| 46 | such that the probe points face towards the arduino on |
| 47 | the finished robot. |
| 48 | - [ ] put 2 zip ties about 2 cm down from the white housing. |
| 49 | this will spread any pulling stress across all terminals. |
| 50 | - [ ] repeat process to make the other sonar cable, |
| 51 | with wire colors in the same order as the first |
| 52 | * make sonar assemblies |
| 53 | - [ ] locate materials |
| 54 | - [ ] 2x sonar |
| 55 | - [ ] 2x sonar holder |
| 56 | - [ ] 2x 6-32 lock nut |
| 57 | - [ ] 2x 6-32x5/8 inch bolt |
| 58 | - [ ] 2x #6 washer |
| 59 | - [ ] locate tools |
| 60 | - [ ] magnetic tray |
| 61 | - [ ] socket wrench |
| 62 | - [ ] 5/16 inch socket |
| 63 | - [ ] 5/64 hex wrench |
| 64 | - [ ] attach binder clip arm to sonar holder |
| 65 | - [ ] fold binder clip arms back as if to open binder clip |
| 66 | - [ ] put #6 washer on 6-32x5/8 inch bolt |
| 67 | - [ ] put bolt through binder clip arm from the inside out |
| 68 | so bolt head will be between opened binder clip arms |
| 69 | - [ ] put sonar holder onto 6-32 bolt |
| 70 | - [ ] finger tighten 6-32 bolt with shiny side toward bolt head |
| 71 | - [ ] use socket, socket wrench and hex wrench to tighten |
| 72 | - [ ] repeat for other sonar holder |
| 73 | - [ ] attach sonars to deck |
| 74 | - [ ] attach sonar holders to deck by clamping binder clip to the deck |
| 75 | - [ ] put a sonar into left holder with sonar cans facing down, |
| 76 | and pins facing right, toward robot center |
| 77 | - [ ] repeat for other sonar, but face pins left, toward robot center |
| 78 | * attach wires to motor |
| 79 | - [ ] locate materials |
| 80 | - [ ] 2x motor |
| 81 | - [ ] 2x 220mm yellow wire |
| 82 | - [ ] 2x 220mm green wire |
| 83 | - [ ] 2x zip tie |
| 84 | - [ ] hot glue |
| 85 | - [ ] electrical tape |
| 86 | - [ ] locate tools |
| 87 | - [ ] hot glue gun |
| 88 | - [ ] soldering iron |
| 89 | - [ ] scissors (or wire cutters) |
| 90 | - [ ] prepare wires |
| 91 | - [ ] strip one side of all 4 wires by about 2mm (1/8 inch) |
| 92 | - [ ] strip other side of all 4 wires by about 2cm (about 1/2 inch) |
| 93 | - [ ] temporarily attach wires to motor |
| 94 | - [ ] orient motor such that metal tabs are at the top, facing you |
| 95 | - [ ] put green wire's short exposed side through motor's right |
| 96 | side metal tab, |
| 97 | running wire down towards shaft |
| 98 | - [ ] wrap wire around shaft and body to keep it oriented and |
| 99 | still during soldering |
| 100 | - [ ] do the same for yellow wire, except put wire through |
| 101 | motor's left side metal tab |
| 102 | - [ ] repeat this process for other motor |
| 103 | - [ ] solder wires to tabs using soldering iron and solder |
| 104 | - [ ] protect motor's metal tabs in the solder joints |
| 105 | - [ ] from electrically connecting to motor's metal band |
| 106 | - [ ] cut strip of about 10cm (4 inches) of electrical tape |
| 107 | - [ ] slide center of tape under wires, sticky side toward motor. |
| 108 | be careful to bend the tabs as little as possible, |
| 109 | to prevent them from snapping |
| 110 | - [ ] wrap tape around motor |
| 111 | - [ ] from breaking |
| 112 | - [ ] place a zip tie around the wires and motor on motor's |
| 113 | round portion, just under square portion |
| 114 | - [ ] put hot glue all over the solder joint and wires to protect |
| 115 | from making accidental electrical connections with stray wires, |
| 116 | and to hold wires mechanically. |
| 117 | * battery solid core wire leads |
| 118 | - [ ] locate materials |
| 119 | - [ ] 1x black battery pack to power arduino, 9v |
| 120 | - [ ] 1x clear battery pack to power motor, 4xAA 6v |
| 121 | - [ ] 2x 35mm black stiff (solid core) wire |
| 122 | - [ ] 2x 35mm red stiff (solid core) wire |
| 123 | - [ ] 2x 35mm black (or clear) heat shrink |
| 124 | - [ ] 2x 35mm red (or clear) heat shrink |
| 125 | - [ ] solder |
| 126 | - [ ] locate tools |
| 127 | - [ ] soldering iron |
| 128 | - [ ] wire stripper |
| 129 | - [ ] heat gun |
| 130 | - [ ] helping hands |
| 131 | - [ ] prep wires for soldering |
| 132 | - [ ] put heat shrink on all battery wires. |
| 133 | match heat shrink color to battery lead |
| 134 | color (unless heat shrink is clear) |
| 135 | - [ ] strip all 4 battery pack leads to about 2cm (1/2 inch) |
| 136 | - [ ] strip in really short segments, about 1mm (1/16 inch) |
| 137 | - [ ] strip both ends of all stiff wires about 1cm (1/4 inch) |
| 138 | - [ ] solder stiff red wire onto clear battery pack red wire |
| 139 | - [ ] grip stiff red wire by one helping hand |
| 140 | - [ ] grip battery red wire by the other helping hand |
| 141 | - [ ] wrap exposed battery wire around exposed stiff wire |
| 142 | - [ ] apply heat from soldering iron, |
| 143 | melt solder with wires, forming solder joint |
| 144 | - [ ] wait for 10 seconds for solder joint to cool |
| 145 | - [ ] unclamp wires from helping hands |
| 146 | - [ ] solder remaining 3 wires on clear and black battery packs: |
| 147 | 2 black, 1 red |
| 148 | - [ ] cover solder joints with heat shrink |
| 149 | - [ ] slide heat shrink so solder joint is in middle of heat shrink. |
| 150 | the purpose of the heat shrink is to keep the solder joint |
| 151 | electrically isolated, and to make a strong mechanical connection. |
| 152 | - [ ] shrink heat shrink with heat gun, starting at end of |
| 153 | wire furthest away from battery pack, working toward battery pack. |
| 154 | * attach breadboard and batteries to top of deck |
| 155 | - [ ] locate materials |
| 156 | - [ ] 1x clear battery pack for powering motors, 4xAA 6v |
| 157 | - [ ] 1x black battery pack for powering arduino, 9v |
| 158 | - [ ] 1x breadboard |
| 159 | - [ ] 10x glue dot |
| 160 | - [ ] locate tools |
| 161 | - [ ] short stubby philips head screw driver |
| 162 | - [ ] attach breadboard |
| 163 | - [ ] 4 glue dots |
| 164 | - [ ] if breadboard has silvery heat spreader |
| 165 | - [ ] remove sticky backing on underside |
| 166 | - [ ] place silvery heat spreader on sticky underside of breadboard |
| 167 | - [ ] attach sticky dots |
| 168 | - [ ] break off 1 glue dot |
| 169 | - [ ] peel paper away from clear. glue dot will stick to clear side |
| 170 | - [ ] place glue dot by holding clear backing into a corner of the |
| 171 | underside of the breadboard. leave clear backing on glue dot. |
| 172 | - [ ] press down firmly on clear backing to make sure sticky dot |
| 173 | stays stuck to breadboard. still leave clear backing on glue dot. |
| 174 | - [ ] repeat this process for all 4 corners of breadboard. |
| 175 | - [ ] now that all 4 corners have a sticky dot with clear backing |
| 176 | - [ ] remove clear backing from all glue dots |
| 177 | - [ ] place breadboard down on deck, just under arduino |
| 178 | - [ ] make sure chip is on right |
| 179 | - [ ] attach clear battery pack for powering motor, 4xAA 6v |
| 180 | - [ ] 4 glue dots |
| 181 | - [ ] short stub screw driver |
| 182 | - [ ] attach glue dots to all 4 corners |
| 183 | - [ ] put short stub philips screw driver through hole 3,2 in deck grid |
| 184 | - [ ] place battery pack with screw hold on screw driver |
| 185 | - [ ] lower battery pack, using screw driver to make sure battery |
| 186 | pack's screw hole lines up with hole 3,2 on the deck |
| 187 | - [ ] attach black battery pack for powering arduino, 9v |
| 188 | - [ ] 2 glue dots |
| 189 | - [ ] short stub screw driver |
| 190 | - [ ] attach a glue dot to each end of the black battery pack |
| 191 | on the side of the battery pack with a screw and without a |
| 192 | switch. |
| 193 | - [ ] use short stub screw driver to guide battery pack so battery |
| 194 | screw hole lines up with grid hole 6, 1 |
| 195 | * make motor assembly |
| 196 | - [ ] put motor mounts on motors |
| 197 | - [ ] locate materials |
| 198 | - [ ] 2x motor |
| 199 | - [ ] 2x motor mount |
| 200 | - [ ] 4x 4-40x1 inch bolt |
| 201 | - [ ] 4x 4-40 lock nut |
| 202 | - [ ] locate tools |
| 203 | - [ ] magnetic tray |
| 204 | - [ ] 1x socket wrench |
| 205 | - [ ] 1x 1/4 inch socket |
| 206 | - [ ] 1x stub screw driver |
| 207 | - [ ] attach motor mount to left motor |
| 208 | - [ ] orient motor mount so that motor nub goes through motor |
| 209 | mount nose, and angle bracket holes are off to left when |
| 210 | looking at motor mount face upright in front of motor |
| 211 | - [ ] put 4-40 bolt through left eye of motor mount face, |
| 212 | then into motor |
| 213 | - [ ] finger tighten 4-40 locking nut onto 4-40 bolt, |
| 214 | put shiny side down, so nylon part of nut is still visible |
| 215 | - [ ] repeat for right eye |
| 216 | - [ ] tighten both bolts with socket wrench and screw driver, |
| 217 | but only after both bolts are through their holes |
| 218 | - [ ] repeat for right motor, but this time, angle bracket holes |
| 219 | will go off to the right when looking at upright motor mount face. |
| 220 | - [ ] put angle brackets on motor mounts |
| 221 | - [ ] locate materials |
| 222 | - [ ] 4x angle bracket |
| 223 | - [ ] 4x 6-32x3/8 inch bolt |
| 224 | - [ ] locate tools |
| 225 | - [ ] magnetic tray |
| 226 | - [ ] 5/64 inch hex wrench |
| 227 | - [ ] face left motor's mount face upright, angle bracket holes on left |
| 228 | - [ ] put 6-32 bolt through upper hole on motor mount |
| 229 | - [ ] bring angle bracket toward bolt from side of motor mount that |
| 230 | has the motor, and nuts on the 4-40 bolts |
| 231 | - [ ] use long arm of hex wrench to spin bolt while bringing angle |
| 232 | bracket's hole closer to the bolt. eventually, the bolt will |
| 233 | catch on the angle bracket hole and pull it in. tighten only a |
| 234 | few turns. the angle bracket will be completly tightened later. |
| 235 | - [ ] put wheels on motors |
| 236 | - [ ] locate materials |
| 237 | - [ ] 2x 2-20x3/8 screw |
| 238 | - [ ] 2x wheel |
| 239 | - [ ] 2x hair tie |
| 240 | - [ ] locate tools |
| 241 | - [ ] magnetic tray |
| 242 | - [ ] stub philip's head screw driver |
| 243 | - [ ] put hair ties on both wheel, it will act as a tire and provide grip |
| 244 | - [ ] put wheel on motor shaft |
| 245 | - [ ] use stub philips screw driver to tighten 2-20 |
| 246 | screw into wheel shaft. |
| 247 | push wheel firmly into motor shaft while tightening. |
| 248 | - [ ] repeat for other wheel |
| 249 | * attach motor assembly to deck |
| 250 | - [ ] make motor assemblies |
| 251 | - [ ] locate materials |
| 252 | - [ ] 4x #6 washer |
| 253 | - [ ] 4x 6-32x3/8 inch bolt |
| 254 | - [ ] 1x left motor assembly |
| 255 | - [ ] 1x right motor assembly |
| 256 | - [ ] locate tools |
| 257 | - [ ] magnetic tray |
| 258 | - [ ] 5/64 inch hex wrench |
| 259 | - [ ] attach left motor assembly to left side of robot |
| 260 | - [ ] put #6 washer on 6-32 bolt |
| 261 | - [ ] put bolt through hole 6,1 on deck |
| 262 | - [ ] use long arm of hex wrench to spin bolt tightening (clockwise) |
| 263 | while bringing left motor assembly angle bracket towards it. |
| 264 | orient assembly so that other angle bracket is on deck grid hole 5,1. |
| 265 | leave it a little loose so motor assembly can pivot second bracket |
| 266 | to line up with hole 5,1 on deck grid. |
| 267 | - [ ] put #6 washer on 6-32 bolt |
| 268 | - [ ] put bolt through hole 5,1 on deck |
| 269 | - [ ] use long arm of hex wrench to spin bolt tightening (clockwise) |
| 270 | while bringing second angle bracket towards it. |
| 271 | - [ ] push motor assembly to the left, out from robot center and |
| 272 | tighten up all 4 of the 6-32 bolts. |
| 273 | pushing out gives the wheel room to spin without rubbing the deck. |
| 274 | - [ ] repeat this process with right motor assembly and |
| 275 | holes 8,5 and 8,6. |
| 276 | * attach caster to deck |
| 277 | - [ ] locate materials |
| 278 | - [ ] 3x 6-32x5/8 inch bolt |
| 279 | - [ ] 3x 6-32 lock nut |
| 280 | - [ ] 3x #6 washer |
| 281 | - [ ] caster holder |
| 282 | - [ ] caster ball |
| 283 | - [ ] locate tools |
| 284 | - [ ] magnetic tray |
| 285 | - [ ] socket wrench |
| 286 | - [ ] 5/16 inch socket |
| 287 | - [ ] 5/64 inch hex wrench |
| 288 | - [ ] attach first bolt |
| 289 | - [ ] put #6 washer on 6-32 bolt |
| 290 | - [ ] put bolt through hole 4,1 on deck grid from top |
| 291 | - [ ] bring middle hole of caster holder towards that bolt |
| 292 | - [ ] finger tighten a locking nut onto the bolt |
| 293 | it will be tightened more after getting all the bolts through the |
| 294 | caster holder |
| 295 | - [ ] put a washer on another bolt, put that bolt through hole |
| 296 | 4,2 on deck and finger tighten nut to it |
| 297 | - [ ] do the same through hole 5,1 |
| 298 | - [ ] use socket, socket wrench and hex wrench to tighten all 3 bolts |