1 * attach arduino to deck
6 - [ ] 4x 6-32x5/8 inch bolt
11 - [ ] 5/64 inch hex wrench
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.
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
31 - [ ] 2x white housing, 4 positions
35 - [ ] 1x wire stripper
36 - [ ] 1x wire cutter (or reuse wire stripper)
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
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
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
56 - [ ] 2x 6-32 lock nut
57 - [ ] 2x 6-32x5/8 inch bolt
62 - [ ] 5/16 inch socket
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
81 - [ ] 2x 220mm yellow wire
82 - [ ] 2x 220mm green wire
89 - [ ] scissors (or wire cutters)
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
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
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
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:
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
161 - [ ] short stubby philips head screw driver
162 - [ ] attach breadboard
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
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
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
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
200 - [ ] 4x 4-40x1 inch bolt
201 - [ ] 4x 4-40 lock nut
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,
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
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
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
253 - [ ] 4x 6-32x3/8 inch bolt
254 - [ ] 1x left motor assembly
255 - [ ] 1x right motor assembly
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
276 * attach caster to deck
277 - [ ] locate materials
278 - [ ] 3x 6-32x5/8 inch bolt
279 - [ ] 3x 6-32 lock nut
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
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
projects / challenge-bot / blob