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The pile of flat stock was waterjet cut by Westar Mfg./Team Whyachi out of 6061 aluminum and 4130 steel. Drawings for this collection of parts along with materials, thicknesses and quantities can be found at http://nearchaos.net/nyxparts1.rar and http://nearchaos.net/nyxparts2.rar. These drawings were done with the intent that most would be made on a waterjet, and as such did not require dimensioning. Each of the drawings that was meant for waterjet cutting has a 1" reference square on the sheet.
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At this point the build was stuck since it would be another day before the 0.201" drill bit would arrive from McMaster-Carr, so I tackled two of the smaller projects. The first was adding padding to the area the flipping attachment would contact the front panel. I used some 3/16" thick rubber cut into a hollow square shape and glued to the aluminum plate. The small pocketed area was added to allow the use of the optional low rpm dual grinding disks, as the main weapon hub would brush against the aluminum plate when spinning continuously.
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First, the dewalt powerdrive kits were bolted to the baseplate. After that, the outer side rails were bolted to the frame. 1/2" shoulder bolts were added with the threaded end on the outside of the wheel guards. The outer wheel guards were removed, allowing for the addition of washers, wheels and the drive shaft. Once all of this was added the outer panel was reattached. The weapon motor shaft goes into an aluminum pillowblock made from scrap, the exact design will be up to you if you replicate it, the only important part is the bushing or bearing used in it must be 1" above the baseplate.
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The final day of the build consists of a great deal of cutting, crimping and soldering with a bit of gluing and velcroing thrown in for good measure. The electrical system consists of the following components: 1 Hobbyking R610 receiver; 1 Team Whyachi MS-1 switch (discontinued, MS-05 should be adequate); 1 Turnigy Nano-tech 6s1p 2650mah Lipoly pack; 1 Digimix V-tail mixer; 3 Holmes Hobbies BR-XL motor controllers; A small pile of deans connectors, wire and bullet plugs
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The BR-XL controllers are velcroed to the baseplate between the drive motors. The motor side of the controllers each connects to 1 motor, the positive lead on the battery side runs to the MS-1 switch, which has the positive battery lead connected to the other terminal. The negative lead for each controller connects directly to the negative battery lead. The drive PWM cables connect to the V-tail mixer, which then connects to the Ail/Ele ports on the rx. The weapon controllers PWM cable goes directly to the rudder port on the rx.
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The foam padding that the battery is resting in is to minimize the risk of shock damage in combat. Once all of the systems were hooked up and calibrated (full calibration instructions come with the BR-XL controllers, only calibrate one at a time to avoid issues) the robot was ready for its first test drive.
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The top armor and the alternate weapons are the last parts to be added to the robot before it is ready for combat. I personally like to add some paint to my robots because I think it makes it more fun for the audience, however that is entirely optional. After doing some testing, it appears that the weapon drive will need a torque limiter for the flipper attachment. For now, the dual disks are working very well: