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  Robotic Madness
  T-1 Part 2

T-1 Rise of the Machines

Polycarb 5mm sheet for track sides.

This part is the platform between the track sides for the batteries.

The shaft on the left side needs to be cut off for the modification for the 3" track system.

Cutting process started.

Universal Hub-02 [ Here ] has two small protrusions either side of the flange, One side needs to be sanded flat [Or turned on a lathe] for the modification.

Left shaft cut off.
Because there are no pre made parts for the 3" track system you have to modify the existing Idler hub, I had to cut of one end as seen in the pic.

Sanding the idler flush.

Drilling out the existing holes so as to tap for 3mm thread.

1 set of tracks temporarly put together, these track sides will be changed for polycarb black sides.

Tracks temporarly fitted.

25mm x 25mm x 2mm alloy for the track base/sides.

Base fitted to track sides.

Ok, These are the new Black polycarb track sides, these replace the clear sides i had before, also note the the sides are a different shape at the front and rear, these were modded after finding better pics of the real machine.

These are the two battery plates that fit inbetween the track sides.

Hex standoff's and battery plate installed.

Nylon tube added to hex standoff's.

Sprockets added to front and back.

One track completed.

As you can see the battery fits real neat into this area, This will be used for the servos and the other side will be used for the Pico ITX.

One track completed.

Base plate fitted to both track sides.

Now to the interesting part, Making the plug for the fiber glass lower body molding. Above pic are two MDF [Medium Density Fiber Board] As you can see i have marked out the sides for fret sawing out, bottom one has been fret sawed. Next clean it up so you have a neat jig, this will be used as a template for a router.

both MDF patterns made and ready for the router machining.

Fret sawing out the polycarb sheet.

Ready for the router.

Polycarb marked out from the template and roughly cut out with a fretsaw.

Jig was bolted to the polycarb sheet and a router used, the straight cutter has a ballrace at the bottom of the cutter, this in turn runs around the MDF pattern and the cutter machines the polycarb to a nice finish.

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