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1 1  {{html wiki="false" clean="true"}}
2 -<body><table border="0" cellpadding="0" cellspacing="0" >
2 +<body bgcolor="#FFFFFF">
3 +<table border="0" cellpadding="0" cellspacing="0" >
3 3   <tbody><tr>
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>
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>
47 47   </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>
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>
50 50   </tr>
51 51   <tr>
52 - <td valign="top" align="left" colspan="2">&nbsp;</td>
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>
53 53   </tr>
54 54   <tr>
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>
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>
72 72   </tr>
73 73   <tr>
74 - <td valign="top" align="left" colspan="2"><br class="pb">
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>
75 75   </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>
76 76   </tr>
77 77   <tr>
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>
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>
95 95   </tr>
96 96   <tr>
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>
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>
124 124   </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>
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>
127 127   </tr>
128 128   <tr>
129 - <td valign="top" align="left" colspan="2"><br class="pb">
130 - </td>
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>
131 131   </tr>
132 132   <tr>
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>
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>
141 141   </tr>
142 142   <tr>
143 - <td valign="top" align="left" colspan="2">&nbsp;</td>
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>
144 144   </tr>
145 145   <tr>
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>
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>
453 453   </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>
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>
456 456   </tr>
457 457   <tr>
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>
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>
519 519   </font></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>
136 + <td align="center" valign="top" ></td>
522 522   </tr>
523 523   <tr>
524 - <td valign="top" align="left" colspan="2"><br class="pb">
525 - </td>
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>
526 526   </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>
556 556  </tbody></table>
557 557  </body>
558 558  {{/html}}
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