Last modified by Eric Nantel on 2023/01/30 15:50
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1 1  {{html wiki="false" clean="true"}}
2 -<body bgcolor="#FFFFFF">
3 -<table border="0" cellpadding="0" cellspacing="0" >
2 +<body><table border="0" cellpadding="0" cellspacing="0" >
4 4   <tbody><tr>
5 - <td valign="top" ><font size="2" face="verdana"><strong>Polycarbonate Information Page<br>
6 - <br>
7 - Updated <!--webbot bot="Timestamp" startspan s-type="EDITED" s-format="%m/%d/%Y" -->07/30/2007<!--webbot bot="Timestamp" i-checksum="12528"
8 - endspan --></strong></font>
9 - <p><font size="2" face="verdana"><b>Why Polycarbonate?<br>
10 - </b>Some of our robots use Polycarbonate. Why, because it is very strong. The image to the right is of me trying really hard to bend one of the
11 - H2 bottom panels. It really hurt holding this long enough&nbsp; for the camera to snap the image. When I let go it returned to its normal flat
12 - shape, no worse for the wear. Now Polycarbonate is not indestructible, but it is very tough. A 1/8" thick x 1/4" wide strip can be
13 - broken, but it takes several back and forth bends before it finally breaks.&nbsp;&nbsp;</font></p>
14 - <p>&nbsp;</p>
4 + <td valign="top" align="left"><font face="Verdana" size="2"><strong>Johnny
5 + 5 Chassis Assembly Instructions Ver. 1.</strong></font>
6 + <p><font face="Verdana" size="2"><strong>Updated <!--webbot bot="Timestamp" s-type="EDITED" s-format="%m/%d/%Y" startspan -->
7 + <!-- #BeginDate format:Am3 -->12/21/2011<!-- #EndDate -->
8 + </strong></font></p>
9 + <p><font face="Verdana" size="2"><b>Safety first!</b> Wear eye protection and never touch a powered robot!</font></p>
10 + <p><font face="Verdana" size="2">Note: Do not use Loctite or thread locks on the assembly. They are not necessary and may cause damage to the
11 + Lexan.</font></p></td>
12 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/j527.jpg" border="2" hspace="10" ><br>
13 + <font size="2" face="Verdana"><strong>Image of the chassis.</strong></font></td>
14 + </tr>
15 + <tr>
16 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
17 + </tr>
18 + <tr>
19 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Lexan Preparation.<br>
20 + </b>The lexan pieces have a protective covering that needs to be removed before assembly. When the laser cuts, the covering melts into the cut
21 + 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
22 + peeled off.</font>
23 + <p><font face="Verdana" size="2">On smaller pieces the coverings can be more difficult to remove. If you have trouble you can gently scrape the
24 + cut edge, then use duct tape to lift the covering off.</font></p>
25 + <p><font face="Verdana" size="2">For further information on lexan, see <a href="https://wiki.lynxmotion.com/info/wiki/lynxmotion/view/support/polycarbonate-info-page/" target="_blank">this page</a>.</font></p></td>
26 + <td align="center" valign="top"><font face="Verdana" size="2"><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/lexan01.jpg" alt="" hspace="10" border="2"><br>
27 + Lexan Preparation.</font></td>
28 + </tr>
29 + <tr>
30 + <td valign="top" align="left" colspan="2">&nbsp;</td>
31 + </tr>
32 + <tr>
33 + <td valign="top" align="left"><strong><font size="2" face="Verdana">Step 1.<br>
34 + </font></strong><font size="2" face="Verdana">Attach four 3" aluminum bars to the inside pair of lexan panels as shown. Use 4-40 x
35 + .375" hex screws.</font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
36 + &nbsp;</font>
37 + <table border="0" >
38 + <tbody><tr>
39 + <td ><font size="2" face="Verdana"><b>8 x</b></font></td>
40 + <td ><font size="2" face="Verdana"><b>4 x</b></font></td>
41 + </tr>
42 + <tr>
43 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></font></td>
44 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/ab3-00.gif" ></font></td>
45 + </tr>
46 + </tbody></table>
15 15   </td>
16 - <td align="center" valign="top " width="320"><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan01s.jpg" border="2" hspace="10" width="320" height="240"><br>
17 - <strong><font size="2" face="verdana">Will it Break? No!<br>
18 - <br>
19 - </font></strong></td>
48 + <td align="center" valign="top" ><font face="Verdana"><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt101.jpg" border="2" hspace="10" ><br>
49 + <font size="2">Figure 1.</font></font></td>
20 20   </tr>
21 21   <tr>
22 - <td valign="top" ><font size="2" face="verdana"><b>Laser-cut Lexan properties</b>&nbsp;<br>
23 - The cut edge has a black residue which can easily be cleaned with a damp rag or paper towel. It is normal and can't be helped. When the residue
24 - is cleaned off, the edge will still be darker than the material. The dark edge is going to be present no matter what color the Lexan is. Most
25 - people like the way the cut edge looks, but there are some who would prefer not to have the dark edge. Technically, it would be possible to try
26 - to polish the edges, but beware it would be a very labor intensive project, and not worth the trouble in my opinion.&nbsp;<br>
27 - <br>
28 - <br>
29 - </font></td>
30 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan02.jpg" border="2" hspace="10" width="320" height="240"><br>
31 - <font size="2" face="verdana">Figure 1.<br>
32 - <br>
33 - </font></td>
52 + <td valign="top" align="left" colspan="2">&nbsp;</td>
34 34   </tr>
35 35   <tr>
36 - <td valign="top" ><font size="2" face="verdana"><b>Lexan protective covering</b>&nbsp;<br>
37 - The Lexan pieces have a protective covering that needs to be removed before assembly. When the laser cuts, the covering melts into the cut edge
38 - which can make removal difficult. If you gently scrape the cut edge with a metal edge, such as a flat blade screw driver, the covering can
39 - easily be separated with a thumb nail.&nbsp;</font></td>
40 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan04.jpg" border="2" hspace="10" width="320" height="240"><br>
41 - <font size="2" face="verdana">Figure 2.<br>
42 - <br>
43 - </font></td>
55 + <td valign="top" align="left"><font size="2" face="Verdana"><strong>Step 2.<br>
56 + </strong></font><font face="Verdana, Helvetica, sans-serif" size="2">Attach 1.5" hex standoffs to the lexan panels as shown. Use 4-40 x
57 + .375" screws.<br>
58 + &nbsp;</font>
59 + <table border="0" >
60 + <tbody><tr>
61 + <td ><font size="2" face="Verdana"><b>12 x</b></font></td>
62 + <td ><font size="2" face="Verdana"><b>12 x</b></font></td>
63 + </tr>
64 + <tr>
65 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></font></td>
66 + <td ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/41500hns.gif" ></td>
67 + </tr>
68 + </tbody></table>
69 + </td>
70 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt102.jpg" border="2" hspace="10" ><br>
71 + <font size="2" face="Verdana">Figure 2.</font></td>
44 44   </tr>
45 45   <tr>
46 - <td valign="top" ><font size="2" face="verdana"><b>Peal and Separate</b><br>
47 - Once it is started the covering easily peels off of the pieces. Note, you only want to scrape the edge. If done properly the pieces will not be
48 - damaged at all.&nbsp;<br>
49 - </font>
50 - <p>&nbsp;</p>
74 + <td valign="top" align="left" colspan="2"><br class="pb">
51 51   </td>
52 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan05.jpg" border="2" hspace="10" width="320" height="240"><br>
53 - <font size="2" face="verdana">Figure 3.<br>
54 - <br>
55 - </font></td>
56 56   </tr>
57 57   <tr>
58 - <td valign="top" ><font size="2" face="verdana"><b>Stubborn Coverings</b><br>
59 - From time to time the coverings can be more difficult to remove. If you have trouble you can gently scrape the cut edge as explained above, then
60 - put a piece of Duct Tape over it, then rip it up. This really works pretty well.&nbsp;</font></td>
61 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan09.jpg" border="2" hspace="10" width="320" height="240"><br>
62 - <font size="2" face="verdana">Figure 4.<br>
63 - <br>
64 - </font></td>
78 + <td valign="top" align="left"><font size="2" face="Verdana"><strong>Step 3.<br>
79 + </strong></font><font face="Verdana, Helvetica, sans-serif" size="2">Attach the motors as shown, using four 3mm x 8mm screws. Make sure the
80 + motor shafts and the hex standoffs are on the same side of the lexan panels.<br>
81 + &nbsp;</font>
82 + <table border="0" >
83 + <tbody><tr>
84 + <td ><font size="2" face="Verdana"><b>4 x</b></font></td>
85 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
86 + </tr>
87 + <tr>
88 + <td ><font face="Verdana" size="2"><b><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/38mphs.gif" ></b></font></td>
89 + <td ><font face="Verdana" size="2"><b>&nbsp;</b></font></td>
90 + </tr>
91 + </tbody></table>
92 + </td>
93 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt103.jpg" border="2" hspace="10" ><br>
94 + <font size="2" face="Verdana">Figure 3.</font></td>
65 65   </tr>
66 66   <tr>
67 - <td valign="top" ><font size="2" face="verdana"><b>The Finish</b><br>
68 - Lexan has a beautiful mirror smooth finish. However, in time it will get tiny surface scratches due to cleaning and normal wear and tear. It
69 - isn't really that noticeable, but under the right conditions it can be visible.&nbsp;Note: this step is optional!</font>
70 - <p><font size="2" face="verdana">There are some options for modifying the finish.</font></p>
71 - <p><font size="2" face="verdana">The Lexan parts can be sand blasted with a fine medium. I especially like the look on the black
72 - components.&nbsp;&nbsp;</font></p>
73 - <p><font size="2" face="verdana">The parts can be lightly sanded by hand, or with a random orbit sander with extra fine sand paper. This is easy
74 - to do, but should be done carefully to avoid removing too much material. The key is to make light even passes with the sander.&nbsp;</font></p>
75 - <p><font size="2" face="verdana">The result is a durable charcoal gray appearance that can't be scratched, because it has been pre-scratched in
76 - every direction.<br>
77 - <br>
78 - Lexan can also be painted, but use paint specifically designed for use with Polycarbonate. Your local hobby shop can help with this.&nbsp;There
79 - has also been some new developments in the paint industry specifically for plastics. Check out Krylon Fusion.&nbsp;<br>
80 - &nbsp;</font></p>
97 + <td valign="top" align="left" colspan="2">&nbsp;</td>
98 + </tr>
99 + <tr>
100 + <td valign="top" align="left"><font size="2" face="Verdana"><strong>Step 4.<br>
101 + </strong></font><font face="Verdana, Helvetica, sans-serif" size="2">Install the hubs onto the motor shafts as shown. Align the hub to be flush
102 + with the end of the motor shaft. Tighten the set screw down firmly.</font></td>
103 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt104.jpg" border="2" hspace="10" ><br>
104 + <font size="2" face="Verdana">Figure 4.</font></td>
105 + </tr>
106 + <tr>
107 + <td valign="top" align="left" colspan="2">&nbsp;</td>
108 + </tr>
109 + <tr>
110 + <td valign="top" align="left"><font size="2" face="Verdana"><strong>Step 5.<br>
111 + </strong>Install the sprockets onto the hubs as shown. Take care to make the teeth on the sprockets line up as shown! Use two 4-40 x .625"
112 + screws per side.</font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
113 + &nbsp;</font>
114 + <table border="0" >
115 + <tbody><tr>
116 + <td ><font size="2" face="Verdana"><b>4 x</b></font></td>
117 + <td ><font size="2" face="Verdana"><b>Sprocket Alignment:</b></font></td>
118 + </tr>
119 + <tr>
120 + <td ><font size="2" face="Verdana"><strong><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4625hscs.gif" ></strong></font></td>
121 + <td ><font face="Verdana" size="2"><strong><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/sprk01.gif" ></strong></font></td>
122 + </tr>
123 + </tbody></table>
81 81   </td>
82 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan03.jpg" border="2" hspace="10" width="320" height="240"><br>
83 - <font size="2" face="verdana">Figure 5.<br>
84 - <br>
85 - </font></td>
125 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt105.jpg" border="2" hspace="10" ><br>
126 + <font size="2" face="Verdana">Figure 5.</font></td>
86 86   </tr>
87 87   <tr>
88 - <td valign="top" ><font size="2" face="verdana">Here is an image of our old Pan and Tilt with the&nbsp;random orbit finish.<br>
89 - &nbsp;</font></td>
90 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexinf06.jpg" border="2" hspace="10" width="320" height="240"><br>
91 - <font size="2" face="verdana">Figure 6.<br>
92 - &nbsp;</font></td>
129 + <td valign="top" align="left" colspan="2"><br class="pb">
130 + </td>
93 93   </tr>
94 94   <tr>
95 - <td valign="top" ><font size="2" face="verdana"><b>Finishing the holes</b><br>
96 - The holes in the panels just need a bit of a push and they just fall out. I am using a 3/32" ball end hex driver here. It works quite well
97 - and it's required to build the kits anyway.&nbsp;&nbsp;<br>
98 - </font></td>
99 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan06.jpg" border="2" hspace="10" width="320" height="240"><br>
100 - <font size="2" face="verdana">Figure 7.<br>
101 - <br>
102 - </font></td>
133 + <td valign="top" align="left"><font size="2" face="Verdana"><strong>Step 6.<br>
134 + </strong></font><font face="Verdana, Helvetica, sans-serif" size="2">Prepare the idler sprockets. Install the two sprocket halves back-to-back
135 + on the long end of the idler hub.</font><font size="2" face="Verdana"> Take care to make the teeth on the sprockets line up as shown!</font><font face="Verdana, Helvetica, sans-serif" size="2">
136 + Attach them with two 3mm x 8mm screws. Make four idler sprocket assemblies.</font>
137 + <p align="center"><font face="Verdana" size="2"><b><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/sprk02.gif" ></b></font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
138 + &nbsp;Figure 6-1.</font></p></td>
139 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt106.jpg" border="2" hspace="10" ><br>
140 + <font size="2" face="Verdana">Figure 6-2.</font></td>
103 103   </tr>
104 104   <tr>
105 - <td valign="top" ><font size="2" face="verdana"><b>Separating the parts</b><br>
106 - Some of the kits have parts nested to simplify packaging and reduce errors. Larger parts can be snapped apart. The smaller parts can be easily
107 - separated with a hobby knife. Be careful! Use a large wood backer and work slowly.&nbsp;<br>
108 - </font></td>
109 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan07.jpg" border="2" hspace="10" width="320" height="240"><br>
110 - <font size="2" face="verdana">Figure 8.<br>
111 - <br>
112 - </font></td>
143 + <td valign="top" align="left" colspan="2">&nbsp;</td>
113 113   </tr>
114 114   <tr>
115 - <td valign="top" ><font size="2" face="verdana"><b>Separating the optional openings</b><br>
116 - Some of the kits have optional openings that need to be cut out before assembly. Carefully press a flat Exacto knife into the opening where the
117 - part is attached to the main panel.&nbsp;<br>
118 - <br>
119 - Caution! Do not attempt to snap these optional openings apart. &nbsp;<br>
146 + <td valign="top" align="left"><b><font face="Verdana" size="2">Step 7.<br>
147 + </font></b><font face="Verdana, Helvetica, sans-serif" size="2">Attach ball bearings to the idler sprockets as directed in either Figure 7-1A or
148 + Figure 7-1B, depending on which version of the idler hub you have. </font><font face="Verdana" size="2">Install the idler sprockets into the
149 + side panel as shown in Figure 7-2. Slide twelve nylon bushings over the nylon standoffs.</font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
150 + &nbsp;</font>
151 + <table border="0" >
152 + <tbody><tr>
153 + <td align="center"><font face="Verdana" size="2"><b><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/sprk03a.gif" ></b><br>
154 + Figure 7-1A.</font></td>
155 + <td align="center"><font face="Verdana" size="2"><b><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/sprk03b.gif" ><br>
156 + </b>Figure 7-1B.</font></td>
157 + </tr>
158 + </tbody></table>
159 + </td>
160 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt109.jpg" ><br>
161 + <font face="Verdana" size="2">Figure 7-2.</font></td>
162 + </tr>
163 + <tr>
164 + <td valign="top" align="left" colspan="2">&nbsp;</td>
165 + </tr>
166 + <tr>
167 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 8.<br>
168 + </b>Install the outer lexan panels as shown to close up the assemblies. Use twelve 4-40 x .375" screws.</font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
169 + &nbsp;</font>
170 + <table border="0" >
171 + <tbody><tr>
172 + <td ><font size="2" face="Verdana"><b>12 x</b></font></td>
173 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
174 + </tr>
175 + <tr>
176 + <td ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></td>
177 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
178 + </tr>
179 + </tbody></table>
180 + </td>
181 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt110.jpg" ><br>
182 + <font face="Verdana" size="2">Figure 8.</font></td>
183 + </tr>
184 + <tr>
185 + <td valign="top" align="left" colspan="2"><br class="pb">
186 + </td>
187 + </tr>
188 + <tr>
189 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 9.<br>
190 + </b>Wrap the 21-segment track assembly around the sprockets, push the axel in and secure with two nylon snap rivet fasteners. These parts are
191 + included with the track kit, not the chassis kit.</font><font face="Verdana, Helvetica, sans-serif" size="2"><br>
192 + &nbsp;</font>
193 + <table border="0" >
194 + <tbody><tr>
195 + <td ><font size="2" face="Verdana"><b>2 x</b></font></td>
196 + <td ><font size="2" face="Verdana"><b>4 x</b></font></td>
197 + </tr>
198 + <tr>
199 + <td ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/pr01.gif" ></td>
200 + <td ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/nrf01.gif" ></td>
201 + </tr>
202 + </tbody></table>
203 + </td>
204 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt111.jpg" ><br>
205 + <font face="Verdana" size="2">Figure 9.</font></td>
206 + </tr>
207 + <tr>
208 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
209 + </tr>
210 + <tr>
211 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 10.<br>
212 + </b>You should now have two assemblies that look something like this.</font></td>
213 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt112.jpg" ><br>
214 + <font face="Verdana" size="2">Figure 10.</font></td>
215 + </tr>
216 + <tr>
217 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
218 + </tr>
219 + <tr>
220 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 11.<br>
221 + </b></font><font face="Verdana, Helvetica, sans-serif" size="2">Attach 1.5" hex standoffs to the bottom panel as shown. Use 4-40 x
222 + .375" screws.<br>
223 + &nbsp;</font>
224 + <table border="0" >
225 + <tbody><tr>
226 + <td ><font size="2" face="Verdana"><b>6 x</b></font></td>
227 + <td ><font size="2" face="Verdana"><b>6 x</b></font></td>
228 + </tr>
229 + <tr>
230 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></font></td>
231 + <td ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/41500hns.gif" ></td>
232 + </tr>
233 + </tbody></table>
234 + </td>
235 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt113.jpg" ><br>
236 + <font face="Verdana" size="2">Figure 11.</font></td>
237 + </tr>
238 + <tr>
239 + <td valign="top" align="left" colspan="2"><br class="pb">
240 + </td>
241 + </tr>
242 + <tr>
243 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 12.<br>
244 + </b>Attach the top panel as shown. </font><font face="Verdana, Helvetica, sans-serif" size="2">Use six 4-40 x .375" screws.<br>
245 + &nbsp;</font>
246 + <table border="0" >
247 + <tbody><tr>
248 + <td ><font size="2" face="Verdana"><b>6 x</b></font></td>
249 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
250 + </tr>
251 + <tr>
252 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></font></td>
253 + <td >&nbsp;</td>
254 + </tr>
255 + </tbody></table>
256 + </td>
257 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt114.jpg" ><br>
258 + <font face="Verdana" size="2">Figure 12.</font></td>
259 + </tr>
260 + <tr>
261 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
262 + </tr>
263 + <tr>
264 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step 15.<br>
265 + </b>Attach the track assemblies to the chassis as shown. </font><font face="Verdana, Helvetica, sans-serif" size="2">Use eight 4-40 x .375"
266 + screws.<br>
267 + &nbsp;</font>
268 + <table border="0" >
269 + <tbody><tr>
270 + <td ><font size="2" face="Verdana"><b>8 x</b></font></td>
271 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
272 + </tr>
273 + <tr>
274 + <td ><font face="Verdana"><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375hscs.gif" ></font></td>
275 + <td >&nbsp;</td>
276 + </tr>
277 + </tbody></table>
278 + </td>
279 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt115.jpg" ><br>
280 + <font face="Verdana" size="2">Figure 15.</font></td>
281 + </tr>
282 + <tr>
283 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
284 + </tr>
285 + <tr>
286 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
287 + 16.<br>
288 + </b>Push the capacitor legs through the holes in the motor terminals. Bend the capacitor legs down onto the terminals as shown.</font></td>
289 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt117.jpg" ><br>
290 + <font face="Verdana" size="2">Figure 16.</font></td>
291 + </tr>
292 + <tr>
293 + <td valign="top" align="left" colspan="2"><br class="pb">
294 + </td>
295 + </tr>
296 + <tr>
297 + <td valign="top" align="left"><b><font face="Verdana" size="2">Step
298 + 17.<br>
299 + </font></b><font face="Verdana" size="2">Push the motor wire connectors onto the motor terminals. Make sure to put the red wires on (+) and the
300 + yellow wires on (-).</font></td>
301 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt118.jpg" ><br>
302 + <font face="Verdana" size="2">Figure 17.</font></td>
303 + </tr>
304 + <tr>
305 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
306 + </tr>
307 + <tr>
308 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
309 + 18.<br>
310 + </b>Install the wiring harness as shown. This switch will be for the 7.2vdc battery that powers the Sabertooth motor controller. Additional
311 + mounting holes allow adding separate power switches for accessories you add to the mobile platform, such as an arm, Johnny 5 torso, etc.</font></td>
312 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt119.jpg" ><br>
313 + <font face="Verdana" size="2">Figure 18.</font></td>
314 + </tr>
315 + <tr>
316 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
317 + </tr>
318 + <tr>
319 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
320 + 19.<br>
321 + </b>Refer to Table 19 for Sabertooth connection information. We've included the switch settings we used for Johnny 5 - you may need to use
322 + different settings for your application. You can find which direction to flip the switches on the card included with the Sabertooth. Route the
323 + motor wires through the holes in the chassis as shown! When the Sabertooth is properly connected and set up, use some double-sided foam tape to
324 + secure it <i>inside</i> the chassis.<br>
325 + &nbsp;</font>
326 + <div align="center">
327 + <center>
328 + <table border="0">
329 + <tbody><tr>
330 + <td >
331 + <div align="center">
332 + <table border="1" bordercolor="#000000" >
333 + <tbody><tr>
334 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0" colspan="2"><font size="2" face="Verdana">Sabertooth
335 + Connections</font></td>
336 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0" colspan="2"><font size="2" face="Verdana">Sabertooth Switch
337 + Settings</font></td>
338 + </tr>
339 + <tr>
340 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">M1A</font></td>
341 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Robot's right motor,<br>
342 + red wire</font></td>
343 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">1</font></td>
344 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Independent Control</font></td>
345 + </tr>
346 + <tr>
347 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">M1B</font></td>
348 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Robot's right motor,<br>
349 + yellow wire</font></td>
350 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">2</font></td>
351 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Disable Exponential</font></td>
352 + </tr>
353 + <tr>
354 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">M2A</font></td>
355 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Robot's left motor,<br>
356 + red wire</font></td>
357 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">3</font></td>
358 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Non-lithium mode</font></td>
359 + </tr>
360 + <tr>
361 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">M2B</font></td>
362 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Robot's left motor,<br>
363 + yellow wire</font></td>
364 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">4</font></td>
365 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">R/C Flip Mode</font></td>
366 + </tr>
367 + <tr>
368 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">B+</font></td>
369 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Battery (+), red wire</font></td>
370 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">5</font></td>
371 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Enable Auto-Calibrate</font></td>
372 + </tr>
373 + <tr>
374 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">B-</font></td>
375 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Battery (-), black wire</font></td>
376 + <td align="center" bordercolor="#808080" bgcolor="#C0C0C0"><font size="2" face="Verdana">6</font></td>
377 + <td align="center" bordercolor="#C0C0C0" bgcolor="#FFFFFF"><font size="2" face="Verdana">Disable Timeout</font></td>
378 + </tr>
379 + </tbody></table>
380 + </div>
381 + </td>
382 + </tr>
383 + <tr>
384 + <td >
385 + <p align="center"><font size="2" face="Verdana">Table 19</font></p>
386 + </td>
387 + </tr>
388 + </tbody></table>
389 + </center>
390 + </div>
391 + </td>
392 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt120.jpg" ><br>
393 + <font face="Verdana" size="2">Figure 19.</font></td>
394 + </tr>
395 + <tr>
396 + <td valign="top" align="left" colspan="2"><br class="pb">
397 + </td>
398 + </tr>
399 + <tr>
400 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
401 + 20.</b><br>
402 + The Sabertooth has a battery elimination feature (BEC). This is useful when connecting the Sabertooth to an R/C receiver as it provides 5vdc at
403 + 500mA. This BEC can power the receiver itself and a couple of servos in low power applications, such as a pan-and-tilt. However, when more
404 + powerful servos are connected to the R/C receiver, you must disable the BEC and provide a separate battery to the R/C receiver and its servos.
405 + It is also necessary to disable the BEC if you are connecting the Sabertooth to an SSC-32.</font>
406 + <p><font face="Verdana" size="2">To disable the BEC, pull the red wire out of the black housings of the CH1 <i>and</i> CH2 wires as shown in
407 + Figure 21. Be sure to cover the exposed wire with heat shrink to prevent accidental short circuits!</font></p>
408 + </td>
409 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt121.jpg" ><br>
410 + <font face="Verdana" size="2">Figure 20.</font></td>
411 + </tr>
412 + <tr>
413 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
414 + </tr>
415 + <tr>
416 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
417 + 21.<br>
418 + </b>This wiring harness is not included in the Tri-Track Chassis kit. We are illustrating what is necessary to install an SSC-32 to control an
419 + arm, Johnny 5 torso, or other servo-based addition. This switch will be used for a 6vdc battery.</font></td>
420 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt122.jpg" ><br>
421 + <font face="Verdana" size="2">Figure 21.</font></td>
422 + </tr>
423 + <tr>
424 + <td valign="top" align="left" colspan="2"><font face="Verdana" size="2">&nbsp;</font></td>
425 + </tr>
426 + <tr>
427 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
428 + 22.</b><br>
429 + If you are using both an SSC-32 and a Bot Board, you will install them as shown in Figure
430 + 22. If you are only using the SSC-32, you will secure
431 + it with the four screws and standoffs.</font></td>
432 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/tt124.jpg" ><br>
433 + <font face="Verdana" size="2">Figure 22.</font></td>
434 + </tr>
435 + <tr>
436 + <td valign="top" align="left" colspan="2"><br class="pb">
437 + </td>
438 + </tr>
439 + <tr>
440 + <td valign="top" ><font size="2" face="Verdana"><b>Step 23.</b><br>
441 + Now it's time to build the base rotate. Insert the stainless steel pins into the plastic bearings as shown.<font face="Verdana, Helvetica, sans-serif" size="2"><br>
442 + &nbsp;</font>
443 + <table border="0" >
444 + <tbody><tr>
445 + <td ><font size="2" face="Verdana"><b>5 x</b></font></td>
446 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
447 + </tr>
448 + <tr>
449 + <td ><font size="2" face="Verdana"><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/basepin.gif" border="2" ></font></td>
450 + <td ><font size="2" face="Verdana"><b>&nbsp;</b></font></td>
451 + </tr>
452 + </tbody></table>
120 120   </font></td>
121 - <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/support/polycarbonate-info-page/WebHome/lexan08.jpg" border="2" hspace="10" width="320" height="240"><br>
122 - <font size="2" face="verdana">Figure 9.<br>
123 - <br>
124 - </font></td>
454 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base01.jpg" border="2" hspace="10" ><br>
455 + <font size="2" face="Verdana">Figure 23.</font></td>
125 125   </tr>
126 126   <tr>
127 - <td valign="top" ><font size="2" face="verdana"><b>Caution!</b><br>
128 - Lexan is the same material used in bullet proof glass. It is very strong, but has one important weakness. In the presence of certain chemicals,
129 - it will "craze". This means it will crystallize, become brittle, and even shatter. One substance in particular to watch out for is 1,
130 - 1, 1 Trichloroethane. This is a solvent, present in some motor cleaners and degreasers, which will crystallize polycarbonate on contact.
131 - Trichloroethane is a liquid CFC and has been removed from use, but may still be out there. Some products have switched to its cousin, 1, 1,
132 - Difluoroethane. While not as vigorously reactive as the previous chemical, it is still capable of crazing Lexan if allowed to come into contact
133 - for too long. Also avoid using Loctite or thread locks on the chassis assembly. They are not necessary and may cause damage to the Lexan.<br>
134 - <br>
458 + <td colspan="2" valign="top">&nbsp;</td>
459 + </tr>
460 + <tr>
461 + <td valign="top" ><font size="2" face="Verdana"><b>Step 24.</b><br>
462 + Install the bearings into the base as shown. They will fit snugly.</font>
463 + <p><font size="2" face="Verdana">Note, the notch in the bottom edge of the base indicates the back.</font></p>
464 + </td>
465 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base02.jpg" border="2" hspace="10" ><br>
466 + <font size="2" face="Verdana">Figure 24.</font></td>
467 + </tr>
468 + <tr>
469 + <td colspan="2" valign="top">&nbsp;</td>
470 + </tr>
471 + <tr>
472 + <td valign="top" ><font size="2" face="Verdana"><b>Step 25.</b><br>
473 + Lay a piece of 400 grit sandpaper on a flat surface and move the base (upside down) in small circles on it. This will remove any imperfections
474 + on the bearings.</font></td>
475 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base03.jpg" border="2" hspace="10" ><br>
476 + <font size="2" face="Verdana">Figure 25.</font></td>
477 + </tr>
478 + <tr>
479 + <td valign="top" align="left" colspan="2"><br class="pb">
480 + </td>
481 + </tr>
482 + <tr>
483 + <td valign="top" ><font size="2" face="Verdana"><b>Step 26.</b><br>
484 + Figure 26 shows the circle pattern on the sandpaper and the inset shows the bearings after any imperfections have been removed.</font></td>
485 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base04.jpg" border="2" hspace="10" ><br>
486 + <font size="2" face="Verdana">Figure 26.</font></td>
487 + </tr>
488 + <tr>
489 + <td colspan="2" valign="top">&nbsp;</td>
490 + </tr>
491 + <tr>
492 + <td valign="top" ><font size="2" face="Verdana"><b>Step 27.<br>
493 + </b>Figure 27 illustrates a typical standard-size servo with its output horn (the round white part) at center position. Make sure your servo
494 + looks like the image, and then carefully remove the servo horn screw and pull the horn straight off of the servo.
495 + The Johnny 5 kit includes either an HS-475 or HS-485.</font>
496 + <p><font size="2" face="Verdana">Make sure you do not lose the servo horn
497 + screw! You will need it later.</font></p>
498 + </td>
499 + <td align="center" valign="bottom" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/servo02.jpg" border="2" hspace="10" ><br>
500 + <font size="2" face="Verdana">Figure 27.</font></td>
501 + </tr>
502 + <tr>
503 + <td valign="top" colspan="2">&nbsp;</td>
504 + </tr>
505 + <tr>
506 + <td valign="top" ><font size="2" face="Verdana"><b>Step 28.</b><br>
507 + Place the servo in the base as shown and screw it in tightly using four #4 tapping screws.<font face="Verdana, Helvetica, sans-serif" size="2"><br>
508 + &nbsp;</font>
509 + <table border="0" >
510 + <tbody><tr>
511 + <td ><font size="2" face="Verdana"><b>4 x</b></font></td>
512 + <td ><b>&nbsp;</b></td>
513 + </tr>
514 + <tr>
515 + <td ><font size="2" face="Verdana"><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/4375phts.gif" border="2" ></font></td>
516 + <td ><b>&nbsp;</b></td>
517 + </tr>
518 + </tbody></table>
135 135   </font></td>
136 - <td align="center" valign="top" ></td>
520 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base05.jpg" border="2" hspace="10" ><br>
521 + <font size="2" face="Verdana">Figure 28.</font></td>
137 137   </tr>
138 138   <tr>
139 - <td valign="top" ><font size="2" face="verdana"><b>Other Information</b><br>
140 - Lexan is a bit on the expensive side compared to foam PVC and acrylic, but the added strength makes it well worth the added cost. It can be
141 - drilled and cut easily using standard wood working tools. Use a low speed on the tool and low feed rates to prevent the plastic from melting to
142 - the tool. Have fun building your robots, and above all be careful!<br>
143 - &nbsp;</font></td>
144 - <td align="center" valign="top" ></td>
524 + <td valign="top" align="left" colspan="2"><br class="pb">
525 + </td>
145 145   </tr>
527 + <tr>
528 + <td valign="top" ><font size="2" face="Verdana"><b>Step 29.<br>
529 + </b>Add a drop of 3-in-1 oil to each bearing.</font></td>
530 + <td align="center" valign="bottom" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/base15.jpg" border="2" hspace="10" ><br>
531 + <font size="2" face="Verdana">Figure 29.</font></td>
532 + </tr>
533 + <tr>
534 + <td colspan="2" valign="top">&nbsp;</td>
535 + </tr>
536 + <tr>
537 + <td valign="top" ><font size="2" face="Verdana"><b>Step 30.</b><br>
538 + Route the base servo's cable through the hole in the back of the base. This will keep the base level to the mounting surface.</font></td>
539 + <td align="center" valign="top" ><img src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/j528.jpg" border="2" hspace="10" ><br>
540 + <font size="2" face="Verdana">Figure 30.</font></td>
541 + </tr>
542 + <tr>
543 + <td colspan="2" valign="top">&nbsp;</td>
544 + </tr>
545 + <tr>
546 + <td valign="top" align="left"><font face="Verdana" size="2"><b>Step
547 + 31.<br>
548 + </b>Install the base rotate using the top screws from the standoffs as
549 + shown.</font>
550 + <p><font face="Verdana" size="2">Now move on to the Johnny 5 Torso
551 + assembly.</font></p>
552 + </td>
553 + <td align="center" valign="top" ><img border="2" src="https://wiki.lynxmotion.com/info/wiki/lynxmotion/download/wheeled-tracked/johnny-5-chassis/WebHome/j527.jpg" ><br>
554 + <font face="Verdana" size="2">Figure 31.</font></td>
555 + </tr>
146 146  </tbody></table>
147 147  </body>
148 148  {{/html}}
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