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+* attach arduino to deck
+ - [ ] locate materials
+ - [ ] 1x arduino
+ - [ ] 1x deck
+ - [ ] 4x spacers
+ - [ ] 4x 6-32x5/8 inch bolt
+ - [ ] 1x 6-32 nut
+ - [ ] locate tools
+ - [ ] safety goggles
+ - [ ] magnetic tray
+ - [ ] 5/64 inch hex wrench
+ - [ ] pliers
+ - [ ] drill
+ - [ ] drill bit
+ - [ ] drill 1 hole, put in 1 bolt
+ - [ ] drill second hole, furthest away from first hole, put in 2nd bolt
+ - [ ] drill 2 remaining holes
+ - [ ] loosen first 2 bolts until arduino comes off
+ - [ ] put in all 4 bolts just enough to place spacers on them
+ - [ ] put arduino on top and tighten all but bottom right bolt
+ - [ ] hold locking nut with pliers, shiny side toward arduino, while
+ tightening last bolt into it.
+* make sonar cables
+ - [ ] locate materials
+ - [ ] 2x 220mm red stiff wire, solid core 22 awg
+ - [ ] 2x 220mm blue stiff wire, solid core 22 awg
+ - [ ] 2x 220mm yellow stiff wire, solid core 22 awg
+ - [ ] 2x 220mm black stiff wire, solid core 22 awg
+ - [ ] 4x zip tie
+ - [ ] 8x terminal
+ - [ ] 2x white housing, 4 positions
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] 1x crimper
+ - [ ] 1x wire stripper
+ - [ ] 1x wire cutter (or reuse wire stripper)
+ - [ ] prepare wires
+ - [ ] strip 1 end of all 8 wires by about 3mm (3/16 inch).
+ the terminal will crimp onto this end
+ - [ ] crimp terminals onto exposed end of wires
+ - [ ] strip other end of all 8 wires by about 2cm (1/2 inch).
+ this end will plug into the breadboard or arduino header
+ - [ ] finish cables
+ - [ ] put crimped ends into housing in the order:
+ black, yellow, blue, red
+ such that the probe points face towards the arduino on
+ the finished robot.
+ - [ ] put 2 zip ties about 2 cm down from the white housing.
+ this will spread any pulling stress across all terminals.
+ - [ ] repeat process to make the other sonar cable,
+ with wire colors in the same order as the first
+* make sonar assemblies
+ - [ ] locate materials
+ - [ ] 2x sonar
+ - [ ] 2x sonar holder
+ - [ ] 2x 6-32 lock nut
+ - [ ] 2x 6-32x5/8 inch bolt
+ - [ ] 2x #6 washer
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] socket wrench
+ - [ ] 5/16 inch socket
+ - [ ] 5/64 hex wrench
+ - [ ] attach binder clip arm to sonar holder
+ - [ ] fold binder clip arms back as if to open binder clip
+ - [ ] put #6 washer on 6-32x5/8 inch bolt
+ - [ ] put bolt through binder clip arm from the inside out
+ so bolt head will be between opened binder clip arms
+ - [ ] put sonar holder onto 6-32 bolt
+ - [ ] finger tighten 6-32 bolt with shiny side toward bolt head
+ - [ ] use socket, socket wrench and hex wrench to tighten
+ - [ ] repeat for other sonar holder
+ - [ ] attach sonars to deck
+ - [ ] attach sonar holders to deck by clamping binder clip to the deck
+ - [ ] put a sonar into left holder with sonar cans facing down,
+ and pins facing right, toward robot center
+ - [ ] repeat for other sonar, but face pins left, toward robot center
+* attach wires to motor
+ - [ ] locate materials
+ - [ ] 2x motor
+ - [ ] 2x 220mm yellow wire
+ - [ ] 2x 220mm green wire
+ - [ ] 2x zip tie
+ - [ ] hot glue
+ - [ ] electrical tape
+ - [ ] locate tools
+ - [ ] got glue gun
+ - [ ] soldering iron
+ - [ ] scissors (or wire cutters)
+ - [ ] prepare wires
+ - [ ] strip one side of all 4 wires by about 2mm (1/8 inch)
+ - [ ] strip other side of all 4 wires by about 2cm (about 1/2 inch)
+ - [ ] temporarily attach wires to motor
+ - [ ] orient motor such that metal tabs are at the top, facing you
+ - [ ] put green wire's short exposed side through motor's right
+ side metal tab,
+ running wire down towards shaft
+ - [ ] wrap wire around shaft and body to keep it oriented and
+ still during soldering
+ - [ ] do the same for yellow wire, except put wire through
+ motor's left side metal tab
+ - [ ] repeat this process for other motor
+ - [ ] solder wires to tabs using soldering iron and solder
+ - [ ] protect motor's metal tabs in the solder joints
+ - [ ] from electrically connecting to motor's metal band
+ - [ ] cut strip of about 10cm (4 inches) of electrical tape
+ - [ ] slide center of tape under wires, sticky side toward motor.
+ be careful to bend the tabs as little as possible,
+ to prevent them from snapping
+ - [ ] wrap tape around motor
+ - [ ] from breaking
+ - [ ] place a zip tie around the wires and motor on motor's
+ round portion, just under square portion
+ - [ ] put hot glue all over the solder joint and wires to protect
+ from making accidental electrical connections with stray wires,
+ and to hold wires mechanically.
+* battery solid core wire leads
+ - [ ] locate materials
+ - [ ] 1x black battery pack to power arduino, 9v
+ - [ ] 1x clear battery pack to power motor, 4xAA 6v
+ - [ ] 2x 35mm black stiff (solid core) wire
+ - [ ] 2x 35mm red stiff (solid core) wire
+ - [ ] 2x 35mm black (or clear) heat shrink
+ - [ ] 2x 35mm red (or clear) heat shrink
+ - [ ] solder
+ - [ ] locate tools
+ - [ ] soldering iron
+ - [ ] wire stripper
+ - [ ] heat gun
+ - [ ] helping hands
+ - [ ] prep wires for soldering
+ - [ ] put heat shrink on all battery wires.
+ match heat shrink color to battery lead
+ color (unless heat shrink is clear)
+ - [ ] strip all 4 battery pack leads to about 2cm (1/2 inch)
+ - [ ] strip in really short segments, about 1mm (1/16 inch)
+ - [ ] strip both ends of all stiff wires about 1cm (1/4 inch)
+ - [ ] solder stiff red wire onto clear battery pack red wire
+ - [ ] grip stiff red wire by one helping hand
+ - [ ] grip battery red wire by the other helping hand
+ - [ ] wrap exposed battery wire around exposed stiff wire
+ - [ ] apply heat from soldering iron,
+ melt solder with wires, forming solder joint
+ - [ ] wait for 10 seconds for solder joint to cool
+ - [ ] unclamp wires from helping hands
+ - [ ] solder remaining 3 wires on clear and black battery packs:
+ 2 black, 1 red
+ - [ ] cover solder joints with heat shrink
+ - [ ] slide heat shrink so solder joint is in middle of heat shrink.
+ the purpose of the heat shrink is to keep the solder joint
+ electrically isolated, and to make a strong mechanical connection.
+ - [ ] shrink heat shrink with heat gun, starting at end of
+ wire furthest away from battery pack, working toward battery pack.
+* attach breadboard and batteries to top of deck
+ - [ ] locate materials
+ - [ ] 1x clear battery pack for powering motors, 4xAA 6v
+ - [ ] 1x black battery pack for powering arduino, 9v
+ - [ ] 1x breadboard
+ - [ ] 10x glue dot
+ - [ ] locate tools
+ - [ ] short stubby philips head screw driver
+ - [ ] attach breadboard
+ - [ ] 4 glue dots
+ - [ ] if breadboard has silvery heat spreader
+ - [ ] remove sticky backing on underside
+ - [ ] place silvery heat spreader on sticky underside of breadboard
+ - [ ] attach sticky dots
+ - [ ] break off 1 glue dot
+ - [ ] peel paper away from clear. glue dot will stick to clear side
+ - [ ] place glue dot by holding clear backing into a corner of the
+ underside of the breadboard. leave clear backing on glue dot.
+ - [ ] press down firmly on clear backing to make sure sticky dot
+ stays stuck to breadboard. still leave clear backing on glue dot.
+ - [ ] repeat this process for all 4 corners of breadboard.
+ - [ ] now that all 4 corners have a sticky dot with clear backing
+ - [ ] remove clear backing from all glue dots
+ - [ ] place breadboard down on deck, just under arduino
+ - [ ] make sure chip is on right
+ - [ ] attach clear battery pack for powering motor, 4xAA 6v
+ - [ ] 4 glue dots
+ - [ ] short stub screw driver
+ - [ ] attach glue dots to all 4 corners
+ - [ ] put short stub philips screw driver through hole 3,2 in deck grid
+ - [ ] place battery pack with screw hold on screw driver
+ - [ ] lower battery pack, using screw driver to make sure battery
+ pack's screw hole lines up with hole 3,2 on the deck
+ - [ ] attach black battery pack for powering arduino, 9v
+ - [ ] 2 glue dots
+ - [ ] short stub screw driver
+ - [ ] attach a glue dot to each end of the black battery pack
+ on the side of the battery pack with a screw and without a
+ switch.
+ - [ ] use short stub screw driver to guide battery pack so battery
+ screw hole lines up with grid hole 6, 1
+* make motor assembly
+ - [ ] put motor mounts on motors
+ - [ ] locate materials
+ - [ ] 2x motor
+ - [ ] 2x motor mount
+ - [ ] 4x 4-40x1 inch bolt
+ - [ ] 4x 4-40 lock nut
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] 1x socket wrench
+ - [ ] 1x 1/4 inch socket
+ - [ ] 1x stub screw driver
+ - [ ] attach motor mount to left motor
+ - [ ] orient motor mount so that motor nub goes through motor
+ mount nose, and angle bracket holes are off to left when
+ looking at motor mount face upright in front of motor
+ - [ ] put 4-40 bolt through left eye of motor mount face,
+ then into motor
+ - [ ] finger tighten 4-40 locking nut onto 4-40 bolt,
+ put shiny side down, so nylon part of nut is still visible
+ - [ ] repeat for right eye
+ - [ ] tighten both bolts with socket wrench and screw driver,
+ but only after both bolts are through their holes
+ - [ ] repeat for right motor, but this time, angle bracket holes
+ will go off to the right when looking at upright motor mount face.
+ - [ ] put angle brackets on motor mounts
+ - [ ] locate materials
+ - [ ] 4x angle bracket
+ - [ ] 4x 6-32x3/8 inch bolt
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] 5/64 inch hex wrench
+ - [ ] face left motor's mount face upright, angle bracket holes on left
+ - [ ] put 6-32 bolt through upper hole on motor mount
+ - [ ] bring angle bracket toward bolt from side of motor mount that
+ has the motor, and nuts on the 4-40 bolts
+ - [ ] use long arm of hex wrench to spin bolt while bringing angle
+ bracket's hole closer to the bolt. eventually, the bolt will
+ catch on the angle bracket hole and pull it in. tighten only a
+ few turns. the angle bracket will be completly tightened later.
+ - [ ] put wheels on motors
+ - [ ] locate materials
+ - [ ] 2x 2-20x3/8 screw
+ - [ ] 2x wheel
+ - [ ] 2x hair tie
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] stub philip's head screw driver
+ - [ ] put hair ties on both wheel, it will act as a tire and provide grip
+ - [ ] put wheel on motor shaft
+ - [ ] use stub philips screw driver to tighten 2-20
+ screw into wheel shaft.
+ push wheel firmly into motor shaft while tightening.
+ - [ ] repeat for other wheel
+* attach motor assembly to deck
+ - [ ] make motor assemblies
+ - [ ] locate materials
+ - [ ] 4x #6 washer
+ - [ ] 4x 6-32x3/8 inch bolt
+ - [ ] 1x left motor assembly
+ - [ ] 1x right motor assembly
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] 5/64 inch hex wrench
+ - [ ] attach left motor assembly to left side of robot
+ - [ ] put #6 washer on 6-32 bolt
+ - [ ] put bolt through hole 6,1 on deck
+ - [ ] use long arm of hex wrench to spin bolt tightening (clockwise)
+ while bringing left motor assembly angle bracket towards it.
+ orient assembly so that other angle bracket is on deck grid hole 5,1.
+ leave it a little loose so motor assembly can pivot second bracket
+ to line up with hole 5,1 on deck grid.
+ - [ ] put #6 washer on 6-32 bolt
+ - [ ] put bolt through hole 5,1 on deck
+ - [ ] use long arm of hex wrench to spin bolt tightening (clockwise)
+ while bringing second angle bracket towards it.
+ - [ ] push motor assembly to the left, out from robot center and
+ tighten up all 4 of the 6-32 bolts.
+ pushing out gives the wheel room to spin without rubbing the deck.
+ - [ ] repeat this process with right motor assembly and
+ holes 8,5 and 8,6.
+* attach caster to deck
+ - [ ] locate materials
+ - [ ] 3x 6-32x5/8 inch bolt
+ - [ ] 3x 6-32 lock nut
+ - [ ] 3x #6 washer
+ - [ ] caster holder
+ - [ ] caster ball
+ - [ ] locate tools
+ - [ ] magnetic tray
+ - [ ] socket wrench
+ - [ ] 5/16 inch socket
+ - [ ] 5/64 inch hex wrench
+ - [ ] attach first bolt
+ - [ ] put #6 washer on 6-32 bolt
+ - [ ] put bolt through hole 4,1 on deck grid from top
+ - [ ] bring middle hole of caster holder towards that bolt
+ - [ ] finger tighten a locking nut onto the bolt
+ it will be tightened more after getting all the bolts through the
+ caster holder
+ - [ ] put a washer on another bolt, put that bolt through hole
+ 4,2 on deck and finger tighten nut to it
+ - [ ] do the same through hole 5,1
+ - [ ] use socket, socket wrench and hex wrench to tighten all 3 bolts