3DoF Lexan Leg Assembly Instructions v3.0

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<td valign="top" align="left">3 DOF Leg Assembly Instructions Rev. 3.

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Updated

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12/20/2011

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Safety first! Wear eye protection and never touch a powered robot!

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Note: Do not use Loctite or thread locks on the assembly. They are not necessary and may cause damage to the

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Lexan.

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Important! You need to build three right legs (following these instructions),Â  and three left legs (by mirroring these instructions)!</td>

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Image of completed Right (robot's right) leg.</td>

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<td valign="top" align="left">Lexan Preparation.

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The lexan pieces have a protective covering that needs to be removed before assembly. When the laser cuts, the covering melts into the cut

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edge which can make removal difficult. If you gently scrape the cut edge with a flat blade screwdriver, the covering can easily be lifted and

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peeled off.

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On smaller pieces the coverings can be more difficult to remove. If you have trouble you can gently scrape the

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cut edge, then use duct tape to lift the covering off.

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For further information on lexan, see <a href="http://www.lynxmotion.com/images/html/infolexa.htm" target="_blank">this page</a>.</td>

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Lexan Preparation.</td>

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<td valign="top" align="left">Step 1.

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Drop the servo in through the hole. The servo tabs should be on top of the Lexan.</td>

Figure 1.</td>

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<td valign="top" align="left">Step 2.

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Install the second lexan piece.</td>

Figure 2.</td>

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<td valign="top" align="left">Step 3.

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Install the other long leg piece.</td>

Figure 3.</td>

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<td valign="top" align="left">Step 4.

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Attach the servo to the lexan pieces using four 4-40 x .750" screws, steel washers, and nylon insert lock nuts. Position the washers on

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top of the servo's mounting tabs as shown.

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Figure 4.</td>

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<td valign="top" align="left">Step 5.

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Slide the small leg piece in between the long ones as shown, and attach it using a 4-40 x .500" hex screw and nylon insert lock nut.

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Figure 5.</td>

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<td valign="top" align="left">Step 6.

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You might want to use sandpaper to smooth off the edges of the bottom of the foot. It

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will be easier on the rubber end cap if you do.</td>

Figure 6.</td>

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<td valign="top" align="left">Step 7.

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Slide the robot foot rubber end cap onto the end of the leg. It might be a tight fit, but if you wiggle it, it will fit.</td>

Figure 7.</td>

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<td valign="top" align="left">Step 8.

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Peel the white cover off of the tape and press the tape onto the hinge as shown.</td>

Figure 8.</td>

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<td valign="top" align="left">Step 9.

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Clean the bottom of the servo with alcohol and allow it to dry. Then peel the green plaid cover off the tape on the hinge, and line the

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hinge up with the edge of the servo. Press the hinge onto the servo very firmly for a full ten seconds to ensure a good bond.</td>

Figure 9.</td>

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<td valign="top" align="left">Step 10.

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Attach a ball bearing to the multi-purpose bracket as shown. Refer to Figure 10-1 for detailed information. Note, this ball bearing is part

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of the chassis kit or "C" bracket, if used.

Figure 10-1.

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Figure 10-2.</td>

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<td valign="top" align="left">Step 11.

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Attach the two multi-purpose brackets as shown, using two 2-56 x .250" screws and 2-56 nuts.

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Figure 11.</td>

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<td valign="top" align="left">Step 12.

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Attach the two "C" brackets as shown, using two 2-56 x .250" screws and 2-56 nuts.

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Figure 12.</td>

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<td valign="top" align="left">Step 13.

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Attach "C" bracket to the multi-purpose bracket as shown. Refer to Figure 13-1 for detailed information.

Figure 13-1.

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Figure 13-2.</td>

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<td valign="top" align="left">Step 14.

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Attach the servo as shown, using the included 3mm hardware. Make sure to route the servo wire as shown.</td>

Figure 14.</td>

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<td valign="top" align="left">Step 15.

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Attach the servo as shown, using the included 3mm hardware. Make sure to route the servo wire as shown.</td>

Figure 15.</td>

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<td valign="top" align="left">Step 16.

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Attach the servo to the "C" bracket using the #2 tapping screws and the diagram below. Make sure that the servo is centered before

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attaching to the "C" bracket.

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Figure 16.</td>

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<td valign="top" align="left">Step 17.

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Install the servo as shown, using the #2 tapping screws and the diagram below. Make sure that the servo is centered before attaching to the

"C" bracket.

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Figure 17.</td>

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<td valign="top" align="left">Step 18.

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Attach the "C" bracket to the servo hinge as shown. Refer to Figure 18-1 for detailed information. Make sure to route the servo wire

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as shown. Leave enough slack for the leg to be able to freely move without pulling on the servo wire.

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Figure 18-1.

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You can now move on to the body assembly instructions.

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Figure 18-2.</td>

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