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We are excited for teams to get started building the 2024 REV ION FRC Starter Bot! Please keep this page bookmarked for future updates and inspiration for building your robot that will compete in the 2024 FRC game, CRESCENDO!
1.75in (x2)
12.5in
16.75in
18in
12.5in
35.5in (x2)
1.125in
12.25in
14.4375in
17.75in
2in
5.5in (x2)
12.5in
17in
35.5in (x2)
and cuts for MAXSwerve Drivetrain
4in
9.5in
26.5in (x2)
32.5in (x2)
Every piece of structural tubing needs to start with a hole 1/2in (or slightly less) from the end where the length measurement is started.
MAXSwerve gives the 2025 Starter Bot great maneuverability, allowing the robot to navigate the field in any direction. This makes tasks like aligning with the reef for coral scoring or repositioning in tight spaces easier. While we have chosen a swerve drive this year, we believe that a flat tank drive can also be an effective drivetrain this year. Direct path cycles without defense will exist since the majority of the scoring is on your side of the field.
A single-stage elevator with an integrated wrist allows for the efficient intake of coral from the human player station with the ability to score on levels one, two, and three of the reef.
Our design emphasizes simplicity over scoring on all levels. Given the number of scoring locations for coral, we felt that the slightly lower max score was worth the trade-off for an easy-to-build, maintain (and repair) design. Teams who want to score on L4, can adjust the geometry of the wrist or add another stage to the elevator, both of which are changes that are accessible upgrades for this design.
A floor intake mechanism mounted to the chassis streamlines the delivery of algae to the processor, allowing your team to contribute to cooperative scoring strategies. The intake subsystem is completely self-contained with both the deployment and intake motors both mounted to the intake itself so this can be left off or added later as desired.
The current 2025 Starter Bot design doesn’t include an endgame mechanism. We felt that while the endgame is an important factor in this game the majority of the scoring will be from coral and algae. While not tested, we believe that teams can design or add cage hooks to the elevator to facilitate shallow cage climbs, expanding their capabilities without overhauling the robot.
Meet the 2025 REV ION FRC Starter Bot! Using the REV ION Build System, this starter bot is designed to give teams a starting point for building their robot while leaving room for iteration, revision, and adaptation to the game’s unique challenges.
Utilizing only REV ION parts, the 2025 REV ION Starter Bot will not require fabrication beyond cutting parts to length. This means your robot can be taken apart and reconfigured as the season evolves or parts can be reused to get a new prototype moving fast.
2024 Version coming soon!
In the meantime, please see the for inspiration!
1/2in Rounded Hex Shaft ()
MAXTube - 2x1 - Light ()
MAXSpline Shaft ()
MAXTube - 2x1 with Grid Pattern ()
MAXTube - 1/2x1/2 ()
2024 Version coming soon!
In the meantime, please see the standard MAXSwerve Drivetrain CAD and MAXSwerve Module Build Guide for inspiration!
Assembly Instructions
Suggested Tools and Suggested Materials
Teams will need to cut some pieces of structural tubing in order to build the 2023 REV ION FRC West Coast Drivetrain. The following sections detail the quantity and length needed for each type of extrusion.
Every piece of structural tubing needs to start with a hole 1/2in (or slightly less) from the end where the length measurement is taken FROM.
2x1 MAXTube:
2x26-1/2in (Front/Rear Rails)
#25 Chain
4x28in (112 links)
Build two of the following Drive Module Subassemblies:
1) Slide 3/4in long #10 spacers inside the 31in long 2x1 MAXTube with MAX Pattern and line them up with the holes shown.
2) Slide 1-1/4in long #10-32 button head screws through the holes in the MAXTube and through the spacers.
3) Position 2-Hole (5in long) 2x1 MAXTubes with MAX Pattern on the exposed ends of the screws. The tubes should be turned on their sides, flush with the top of the 31in tube, and located 7in from the end of the 31in tube. The side of the 31in tube these tubes are installed on will become the “outboard” side of the drive module.
4) Install nylock nuts on the ends of the screws, inside the 5in long tubes. The nuts will engage with the slots inside the MAXTubes, so no tool is necessary to hold them in place. Tighten the screws down.
5) Locate the middle MAXSpline on the 31in tube. Insert a Structural MAXHub in the two (2) MAXSplines on either side of the center one on the outboard side of the tube.
Rotate the hubs so that their threaded holes are located along the centerline of the tube (i.e. on the left or right side).
6) Insert two (2) plastic MAXHubs aligned with the Structural MAXHubs on the inboard side of the tube.
Rotate the hubs so that their threaded holes are on the opposite side (left/right) from the Structural MAXHubs.
7) Fasten the MAXHubs in place with one 1in long #10-32 button head screw and one 1in long #10-32 socket head screw for each MAXHub pair. The socket head screw should be installed through the plastic MAXHub and threaded into the Structural MAXHub. The button head screw should be installed through the Structural MAXHub and threaded into the plastic MAXHub.
8) Insert two 2-1/2in long rounded hex shafts into the plastic MAXHubs (one shaft in each). Push them in all the way up against the Structural MAXHub.
9) Fasten the shafts in place with 1/2in long #10-32 button head screws.
1) Build two of the following: a. Insert two aluminum MAXHubs into each side of a traction wheel. Rotate the hubs so that their threaded holes are 180 degrees apart. b. Fasten the MAXHubs in place with two 1in long #10-32 socket head screws.
2) Build four of the following: a. Insert two aluminum MAXHubs into each side of an omni wheel. Rotate the hubs so that their threaded holes are 180 Degrees apart. b. Fasten the MAXHubs in place with two 1in long #10-32 socket head screws.
1) Form two of the #25 chain lengths into a loop. This can be accomplished with a chain tool or by removing an extra link and using a connecting link.
2) Place the chain loops on either side of a 16T #25 double sprocket.
3) Insert a 6in long Hex Shaft into the 16T double sprocket.
4) Loop the opposite ends of the chains around two more 16T #25 double sprockets (one for each chain). Ensure that each chain is installed on either the front or back of the sprockets (e.g. not on the front of one sprocket and on the back of the other sprocket).
5) Slide two 4in long Hex Shafts into the outer sprockets (one in each sprocket).
6) Slide two Rounded Hex Bearings onto the ends of the shafts (one on each shaft).
7) Install two Rounded Hex Bearings in the center MAXSpline of the MAXTube (one on either side of the tube).
8) Line up the chain assembly with the MAXTube and insert the center shaft into the bearings in the middle of the tube. The sprockets and chain should be located on the inboard side.
Insert the shaft through both bearings, but don’t push the middle sprocket all the way against the bearing.
9) Slide the 4in shafts with bearings into their associated MAXSplines in the MAXTube. Slide the sprockets and chain up against the bearings as this is done. This may require a significant amount of force to achieve, as the chain is supposed to be very tight.
10) Slide two Rounded Hex Bearings onto the outboard ends of the 4in shafts and into the MAXSplines in the MAXTube. Tension will have to be applied to the chain in order to get the bearings into the MAXSplines. The shafts may be used as levers to tension the chain and line up the bearings. This may require a significant amount of force to achieve, as the chain is supposed to be very tight.
11) Install one 1/8in wide Shaft Spacer and one 1/16in wide Shaft Spacer onto the outboard side of the center shaft.
12) Install one of the traction wheel assemblies onto the center shaft. If necessary, slide the shaft so that it is flush with the face of the MAXHub on the outside of the wheel. It may require tapping the shaft with a small rubber mallet to move it with the chain tension in place.
13) Install two of the omni wheel assemblies onto the outer shafts. If necessary, slide the shafts so that they are flush with the face of the MAXHub on the outside of the wheel. It may require tapping the shaft with a small rubber mallet to move it with the chain tension in place.
14) Retain the three wheels with Shaft End Screws.
15) On the inboard side of the center shaft, install one 1/16in wide Shaft Spacer, one 1/4in wide Shaft Spacer, and one 1/2in wide Shaft Spacer.
16) On the inboard side of each of the outer shafts, install one 1/8in wide Shaft Spacer and one 1/2in wide Shaft Spacer.
17) Retain the outer shafts with Shaft End Screws.
2) Ensure that the body screws put into the lower spacers are inserted with the screw head on the opposite side of the motors. The nylock nuts must be removed for this step as well.
3) Slide the gearbox onto the end of the center shaft and thread the exposed screws into the ends of the standoffs (2-1/2in hex shafts). Tighten the screws down.
4) Retain the center shaft with a Shaft End Screw.
1) Arrange the two assembled drive modules and the two 26-1/2in long tubes (“front/rear rails”) as shown. The ends of the front/rear tubes should be flush with the 5in long MAXTubes between the wheels.
2) Position eight 90 Degree brackets on each corner, top and bottom, and use 3/16in rivets to rivet them in place.
Want to integrate this drivetrain with your 2023 Starter Bot? Check out the Integration Steps!
Yellow rigid plastic cones are one of the game pieces for this year's CHARGED UP game. There are 54 cones total on the playing field, including in the Substation area. The average weight of the cones is approximately 1lb 7oz.
Purple inflatable cubes are also one of the game pieces for this year's CHARGED UP game. There are 44 cubes total on the playing field, including in the Substation area. The average weight of the cubes is approximately 2.5oz.
Each cube is made of purple PVC fabric and is marked with a FIRST logo. A cube has rounded corners, may not have flat surfaces, and the length, width, and height of the sides may not be equal dimensions.
Cubes are expected to experience wear during matches, and small holes may be patched with electrical tape.
Each field has two Charge Stations, one for each alliance, located in their corresponding communities. Each Charge Station consists of the main pivoting frame, lead-in ramps, and support structure. The main pivoting frame is mounted to the base frame via a set of 4 double hinges.
A robot earns points for its alliance by docking on or engaging with its Charge Station.
A Substation is an assembly used to move game pieces, like cubes and cones, from humans to robots or onto the field. There are 2 types of Substations in each Substation Area: a Single Substation and a Double Substation. Each Substation contains a Portal- a three-dimensional volume through which humans transfer game pieces to robots or the field.
Each Alliance's Double Substation is attached to and in-line with their opponent’s Alliance Wall. Each Single Substation is in-line with the guardrail.
A 20ft wide by 9ft 10-1/4in deep infinitely tall volume, formed by, and including the Alliance Wall, edge of the carpet, and Alliance colored tape.
Below is a link to download the code for a 2024 REV ION FRC Starter Bot on GitHub! This example uses a MAXSwerve Drivetrain and is programmed in Java.
If you are only using part of our design on your robot, you can still use this code to help you program! To find the code for each individual mechanism, navigate to:
Then, select one of the following subsystem programs to use
ArmSubsystem.java- raising and lowering the intake and launcher, also controls the climb
IntakeSubsystem.java - intaking notes and feeding them to the launcher
LauncherSubsystem.java - stopping and starting the flywheels on the launcher
In addition to referencing the subsystem code, you will need to look at RobotContainer.java for information about button bindings, constant/variable names, and function names. To find RobotContainer.java navigate to:
CHARGED UP, presented by Haas, is an exciting and fast-paced competition that invites two competing alliances to bring energy to their community by retrieving cones and cubes and scoring them in a grid. The game features both autonomous and driver-controlled periods, during which teams can score points by retrieving and scoring game pieces, as well as docking on or engaging with their charge station. Teams will need to strategize and work together in order to emerge as the top alliance in this exciting game.
FIRST Robotics Challenge Game and Resources LINK
Details in this section of the guide may not reflect the most recent game rule updates. Always refer to the official game manual before making final decisions!
For a full detailed scoring summary, see section 6.4.3 Point Values in the official 2023 Game Manual.
Mobility
3
-
-
Game Pieces - Bottom Row
3
2
-
Game Pieces - Middle Row
4
3
-
Game Pieces - Top Row
6
5
-
Link - 3 Nodes in a row contain Game Pieces
-
5
-
Robot Docked and not Engaged
8 (1 robot max in AUTO)
6
-
Robot Docked and Engaged
12 (1 robot max in AUTO)
10
-
Park
-
2
-
Sustainability bonus
-
-
1
Activation Bonus
-
-
1
Tie
-
-
1
Win
-
-
2
If you are unfamiliar with the game field structure, the following view can give insight into the different elements and their locations.
The first step to any good FRC Game strategy is a full, in-depth understanding of the game. Strong knowledge of scoring achievements, point values, and game rules help teams develop a game strategy that maximizes their scoring ability. Once the knowledge is built, the game can be broken down into data points for analysis.
A commonly used metric in the competitive robotics world is points per second. Basing your game strategy based on the number of points you can gain per second (or even per game period), will help your team make the mechanical choices best for you!
Remember to always strategize and build within your resources! Not all teams will have access to the same resources, whether it is parts or people. A strategy that seems to yield the most points per second on paper may not be as successful as a strategy that focuses on maximizing accuracy.
One of the first steps we recommend your team take is to plan out your potential strategy for playing the game. After taking time to read through the rules, sitting down to brainstorm strategies and ideas for build season is an exciting and challenging task. It's important to involve all team members in the brainstorming process, as diverse perspectives and expertise can lead to innovative and effective solutions. During the brainstorming session, it's also important to keep an open mind and embrace creativity, as this can lead to new and unexpected ideas that could give the team a competitive edge.
The scoring and match strategy for CHARGED UP involves maximizing points earned through various actions, such as scoring game pieces on grids, completing links, docking on and/or engaging with the charge station, and parking.
A team has to have a good understanding of the point system and the specific criteria for earning points in order to develop an effective scoring strategy. It may also be beneficial to focus on actions that earn the most points per action, such as completing links, which is worth more points than scoring a single game piece.
Additionally, teams should consider aiming to score game pieces in a way that maximizes their chances of earning links. This could involve prioritizing certain rows or nodes on the grid to focus on scoring in. It could also be important to have a strategy for the endgame, where robots attempt to park, dock, and engage with their charge station or continue to score game pieces. Overall, teams need to have a good understanding of the point system and the specific criteria for earning points. The team may choose to aim to score game pieces in a way that maximizes their chances of earning links and aim to engage and dock with the charge station as many times as possible.
Some questions to consider asking yourselves during this process are:
What are our options for scoring during the different match periods (Autonomous, Teleoperated, End Game)?
What are things that our robot MUST be able to do to be successful in this year's game? (ie- navigate over certain terrains like cable protectors or the charging station, etc.)
Are there any aspects of the game that our team would like to focus on? April Tags are new this year and could be a fun challenge for vision processing!
Check out this video from the Kettering Robot in 3 Days team about Scoring and Strategy:
Watch the video below, presented by First Updates Now and brought to us by Kettering University, to see what seven of the most important Robot and Game Rules are to know for CHARGED UP!
However, in order to get a true sense of the 2023 FIRST Robotics Competition game, CHARGED UP, you must dive into the manual. The manual provides in-depth explanations regarding all of the components necessary for this challenge. It outlines how teams should approach the field, collect cubes and cones to charge, climb a tower, and deploy their robot into a goal to score points. With colorful diagrams and detailed descriptions of the custom components and scoring system, the manual helps teams understand exactly what is required for them to excel at this competition.
Be sure to read up on CHARGED UP before gearing up for an exciting competition season!
1) Assemble a 2 Motor Drivetrain Gearbox with the gearset for 6in wheels with the pinions for the desired speed. If you are unsure of how to do this, you can find the directions here:
3) Assembly is complete- begin the rest of your robot assembly, or begin following the !
The 2025 REV ION Starter Bot drivetrain is designed with the MAXSwerve Module. Before you begin this section of the build guide you will need to assemble four MAXSwerve Modules.
For ease of wiring, we suggest building 2 modules with Left-Hand motor orientation and 2 modules with Right-Hand motor orientation.
Get:
24 - MAXTube Internal Support 2x1
4 - MAXTube 2x1 with Grid Pattern - cut to 18in
Insert 3 MAXTube Internal Supports into each end of the MAXTube pieces. Take care to ensure they do not fall out before securing them in the next step.
Get:
4 - MAXSwerve Module, fully assembled
12 - #10-32 Button Head Screws x 3in
12 - #10-32 Low Profile Nylon Lock Nut
2 - Assemblies from Step #1
Attach one MAXSwerve Module to each end of an 18in MAXTube piece. We recommend mounting one right-hand and one left-hand module so that the wires point toward each other.
Secure the MAXSwerve Modules to the MAXTube using screws so that each screw passes through a MAXTube Internal Support and the Nylon Lock Nt is on top.
Make two of these.
Get:
8 - #10-32 Button Head Screws x 3in
8 - #10-32 Low Profile Nylon Lock Nut
2 - Assemblies from Step #1
Connect the two MAXSwerve Module rails with two screws on each side so that each screw passes through a MAXTube Internal Support and the Nylon Lock Nut is on top. Note - Leave the middle hole and MAXTube Internal Support empty, it will be used in a later step
Get:
4 - SPARK MAX Motor Controller
4 - Absolute Encoder Adapter
4 - JST PH 6-pin Extension Cable - 30cm
12 - WAGO 221 Inline Splicing Connector
Zip Ties
For each MAXSwerve Module, wire the NEO 550 and Through Bore Encoder to a SPARK MAX with an Absolute Encoder Adapter installed in the data port. Then, secure the SPARK MAX to the module’s SPARK MAX Mounting Bracket using zip ties.
Note - Placing a zip tie over the Absolute Encoder Adapter and aligned with its notches is highly recommended to ensure a secure connection
Get:
5 - MAXTube Internal Support 2x1
1 - MAXTube with MAX Pattern cut to 23in
Get:
2 - MAXTube Endcap - 2x1
4 - #10-32 Button Head Screws x 5/16in
Insert MAXTube Endcaps into both ends of the MAXTube with MAXPattern. Secure both MAXTube Endcaps with 2 screws, onon the top and bottom of the 1in face of the MAXTube.
Get:
6 - #10-32 Button Head Screws x 1 1/2in
Add this MAXTube to your MAXSwerve Drivetrain as the first middle brace. The factory edge, used as a reference in the above steps, should be mounted towards the front of the robot indicated by the green arrow.
Get:
4 - MAXTube Internal Support 2x1
1 - MAXTube with MAX Pattern cut to 23in
Counting from the first complete hole on the factory edge of the 35.5in , insert 4 MAXTube Internal Supports so that they align with holes 22, 23, 24, and 28
Get:
2 - MAXTube Endcap - 2x1
4 - #10-32 Button Head Screws x 5/16in
Insert MAXTube Endcaps into both ends of the MAXTube with MAXPattern. Secure both MAXTube Endcaps with 2 screws, onon the top and bottom of the 1in face of the MAXTube.
Get:
6 - #10-32 Button Head Screws x 1 1/2in
Add the MAXTube to your MAXSwerve Drivetrain as the second middle brace. The factory edge, used as a reference in the above steps, should be mounted towards the front of the robot indicated by the green arrow as shown.
Get:
2 - 1/2in Rounded Hex Bearing - Flanged - 1.125in OD
Place one Flanged Bearing on either side of the right-side brace MAXTube in the 7th MAXSpline from the front of the robot.
Get:
1 - NEO Vortex Brushless Motor
1 - SPARK Flex Motor Controller, with docking hardware
1 - Vortex MAXPlanetary Input Kit
2 - #10-32 Socket Head Screws x 1/2in
2 - 5:1 MAXPlanetary Cartridge
1 - MAXPlanetary 1/2in Hex Socket Output
1 - 10-32 Button Head Screw 1/2in
1 - 1/2in Rounded Hex Shaft - 2.0in - Tapped
2 - #10-32 Socket Head Screws x 1-1/2in
Assemble a 25:1 MAXPlanetary Gearbox with a 2.0in output shaft driven by a NEO Vortex
Get:
2 - #10-32 Button Head Screws x 1-1/2in
Mount the MAXPlanetary Gearbox as shown, ensuring that the bearings stay in place. Note: At this time consider which direction your SPARK Flex is facing and the rest of your robot’s wiring. For the 2025 Starter Bot, we chose to have the Status LED face towards the back of the robot.
Get:
4 - 1/2in Rounded Hex Bearing - Flanged - 1.125in OD
Place one Flanged Bearing on either side of both MAXTube bracing pieces in the 5th MAXSpline from the front of the robot.
Get:
1 - 1/2in Rounded Hex Shaft cut to 18in
2 - 1/2in Hex Shaft Spacer - 1/16in
2 - #25 Hub Sprocket - 1/2in Hex - 16T
2 - 2 Piece 1/2" Hex Plastic Shaft Collar
Insert the 1/2in Rounded Hex Shaft through one set of bearings and then add a 1/16 Spacer, 16T Sprocket, 1/2in Hex Shaft Collar, 1/2in Hex Shaft Collar, 16T Sprocket, and 1/16 Spacer to the hex shaft before exiting through the other set of bearings.
Note: do not fully tighten the shaft collars at this time.
Get:
2 - #25 Hub Sprocket - 1/2in Hex - 16T
1 - 48 Link # 25 Chain Loop
Connect the 1/2in Hex output from the MAXPlanetary Gearbox to the 18in Piece of 1/2in Rounded Hex Shaft with 16T sprockets and a 48 link chain loop.
Get:
1 - 1/2in Hex Shaft Spacer - 1/8in
2 - #10-32 Shaft End Screw
Place the 1/8in Hex Shaft spacer on the output shaft of the MAXPlanetary Gearbox. Then, secure the Sprockets and chain to the 1/2in Rounded Hex Shaft with Shaft End Screws.
Get:
1 - 1/2in Hex Shaft Spacer - 1/2in
2 - #10-32 Shaft End Screw
Secure the other side of the 18in long Rounded Hex Shaft with a 1/2in Hex Shaft Spacer and a Shaft End Screw. Then,
Get:
Belly Pan Material - Cut to desired size
22 - 3/16in Rivets - 0.251-0.375in Grip Length
Rivet the belly pan to the underside of the MAXSwerve Drivetrain as shown.
Note: We recommend pausing here to mount your robot’s main electronics.
Get:
4 - Ballast Block - 3in x 2in x 1in
4 - #10-32 Button Head Screws x 1-1/4in
Connect 2 Ballast Blocks using 2 screws as shown. Make 2 of these.
Get:
4 - #10-32 Button Head Screws x 2-3/4in
Mount both Ballast Block assemblies to the back of the robot with two 2.75in screws each as shown
Get:
1 - MAXTube - 2x1 with Grid Pattern cut to 2in
1 - MAXTube Internal Support 2x1
Place one MAXTube Internal Support within the 2in Piece of MAXTube as shown.
Get:
2 - #10-32 Button Head Screws x 2-1/4in
2 - #10-32 Low Profile Nylon Lock Nut
Mount the MAXTube piece to the left brace with screws and nuts.
Get:
4 - MAXTube Endcap 2x1
8 - #10-32 Button Head Screws x 2-1/4in
Attach one MAXTube Endcap to each corner of the Drivetrain as shown in the picture.
Note: The top left MAXTube Endcap is not symmetrical with the others.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 17in
2 - MAXTube Endcap 2x1
. Insert one MAXTube endcap into each end of the 17in piece of MAXTube.
Get:
14 - #10-32 Button Head Screws x 3/8in
Secure both Endcaps with 7 screws each. Leave both middle spots open on one of the 2in sides of the MAXTube.
Get
1 - MAXTube 2x1 with Grid Pattern - cut to 5.5in 5 - MAXTube Internal Spacer 2x1
Add 5 MAXTube Internal Spacers to a 5.5in piece of MAXTube as shown in the image.
Get:
3 - #10-32 Button Head Screws x 1-1/2in
Attach the 5.5in section of MAXTube to the right side of the 17in MAXTube piece using 3 Screws and the existing MAXTube Endcap.
Note: The 17in MAXTube should be positioned so that the 2in side with only 4 screws showing is facing the builder.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 5.5in
5 - MAXTube Internal Spacer 2x1
Add 5 MAXTube Internal Spacers to a 5.5in piece of MAXTube as shown in the image.
Get:
3 - #10-32 Button Head Screws x 1-1/2in
Attach the 5.5in section of MAXTube to the right side of the 17in MAXTube piece using 3 Screws and the existing MAXTube Endcap.
Get:
1 - MAXTube 2x1 with - Light - Grid Pattern - cut to 35.5in
2 - MAXTube Internal Spacer - 2x1 Light
Add two MAXTube Internal Spacers to the MAXTube, they should align with the 56th and 58th holes from the factory edge.
Get:
3 - #10-32 Button Head Screws x 2-1/4in
3 - #10-32 Low Profile Nylon Lock Nut
Connect the 35in piece of MAXTube to the existing assembly as shown using screws and nuts. The screws will pass through the MAXTube Internal Spacers from previous steps.
Get:
Get: 1 - MAXTube 2x1 with - Light - Grid Pattern - cut to 35.5in
2 - MAXTube Internal Spacer - 2x1 Light
Add two MAXTube Internal Spacers to the MAXTube, they should align with the 56th and 58th holes from the factory edge..
10. Get:
3 - #10-32 Button Head Screws x 2-1/4in
3 - #10-32 Low Profile Nylon Lock Nut
Connect the 35in piece of MAXTube to the existing assembly as shown using screws and nuts. The screws will pass through the MAXTube Internal Spacers from previous steps.
Get:
2 - MAXTube Endcap 2x1 4 - #10-32 Button Head Screws x 2-1/2in
Attach 2 MAXTube Endcaps to the MAXTube support as shown. Use 2 screws for each MAXTube Endcap.
Get:
2 - MAXTube Endcap 2x1 - Light
4 - #10-32 Button Head Screws x 3/8in
Cap the ends of the 35.5in MAXtube Sections with MAXTube Endcaps. Secure each endcap with 2 screws, one on each 1in side of the MAXTube.
Get:
1 - MAXSpline Bracket - Stacked
2 - #10-32 Button Head Screws x 5/16in
Mount the MAXSpline Bracket to the MAXTube as shown with Screws.
Get:
1 - MAXSpline Bracket - Stacked
1 - #10-32 Button Head Screws x 5/16in
Add a second MAXSpline Bracket to the opposite of the MAXTube.
Get:
1 - #10-32 Button Head Screws x 1-1/2in
1 - #10-32 Low Profile Nylon Lock Nut
Secure the two MAXSpline Brackets to the MAXTube with a screw and nylon lock nut.
Get:
4 - #10 Standoff - 1.00in
8 - #10-32 Button Head Screws x 1/2in
Add 4 #10 standoffs between the MAXSpline Brackets using screws to secure in place.
Get:
2 - 1/2in Rounded Hex Bearing - Flanged - 1.125in OD
Add a 1/2in Rounded Hex Bearing in each of the MAXSpline Brackets. The flange of the bearing should be on the outside of the brackets.
Get:
1 - 1/2in Rounded Hex Shaft - 2.0in - Tapped
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - #25 Hub Sprocket - 1/2in Hex - 16T
2 - #10-32 Shaft End Screw
Insert a Shaft End Screw on one side of a 2in long piece of 1/2in Rounded Hex Shaft, and then slide on a 1/4in spacer. Pass this assembly through the bearings so that the spacer is on the outside of the assembly. To secure the hex shaft in place, add the 16T Sprocket and then install another shaft end screw.
Get:
1 - MAXSpline Bracket - Stacked
2 - #10-32 Button Head Screws x 5/16in
Mount the MAXSpline Bracket to the MAXTube as shown with Screws.
Get:
1 - MAXSpline Bracket - Stacked
1 - #10-32 Button Head Screws x 5/16in
Add a second MAXSpline Bracket to the opposite of the MAXTube.
Get:
1 - #10-32 Button Head Screws x 1-1/2in
1 - #10-32 Low Profile Nylon Lock Nut
Secure the two MAXSpline Brackets to the MAXTube with a screw and nylon lock nut.
Get:
4 - #10 Standoff - 1.00in
8 - #10-32 Button Head Screws x 1/2in
Add 4 #10 standoffs between the MAXSpline Brackets using screws to secure in place.
Get:
2 - 1/2in Rounded Hex Bearing - Flanged - 1.125in OD
Add a 1/2in Rounded Hex Bearing in each of the MAXSpline Brackets. The flange of the bearing should be on the outside of the brackets.
Get:
1 - 1/2in Rounded Hex Shaft - 2.0in - Tapped
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - #25 Hub Sprocket - 1/2in Hex - 16T
2 - #10-32 Shaft End Screw
Insert a Shaft End Screw on one side of a 2in long piece of 1/2in Rounded Hex Shaft, and then slide on a 1/4in spacer. Pass this assembly through the bearings so that the spacer is on the outside of the assembly. To secure the hex shaft in place, add the 16T Sprocket and then install another shaft end screw.
Get:
8 - #10-32 Button Head Screws x 1/2in
2 - MAXLift End-mount Bearing Block
Mount two MAXLift Bearing Blocks to the top of the assembly using three screws each. The bearings should be facing the inside of the lift. Set aside
Get:
1 - NEO V1.1 Brushless Motor
1 - MAXPlanetary Base Kit
2 - #10-32 Socket Head Screws x 1/2in
2 - 5:1 MAXPlanetary Cartridge
1 - 4:1 MAXPlanetary Cartridge
1 - 10-32 Button Head Screw 1/2in
1 - 1/2in Rounded Hex Shaft - 1.75in - Tapped
2 - #10-32 Socket Head Screws x 1-1/2in
Assemble a 20:1 MAXPlanetary Gearbox with a 1.75in output shaft driven by a NEO V1.1 Motor.
Get:
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - 1/2in Hex Shaft Spacer - 1/16in
1 - 1/2in Hex Shaft Spacer - 1/8in
Add three spacers to the MAXPlanetary Gearbox’s output.
Set this aside, we recommend standing the assembly up on the back end of the motor.
Get:
1 - MAXSpline 2x1 Bearing Blocks - Threaded Plate
1 - 1/2in Rounded Hex Bearing - Flanged - 1.125in OD
Insert a bearing into the MAXSpline Bore of the Threaded Plate from one MAXSpline 2x1 Bearing Block pack. The flange of the bearing will sit in the recessed portion of the plate.
Get:
1 - MAXSpline 2x1 Bearing Blocks - Clearance Plate
2 - #10-32 Button Head Screws x 1-1/2in
2 - #10 Spacer - 3/4in
Use screws to attach the Clearance Plate to the Threaded Plate with two 3/4in #10 spacers between them. Both screws should be on the same short edge of the MAXSpline Bearing Block
Get:
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - #25 Hub Sprocket - 1/2in Hex - 16T
1 - 20:1 MAXPlanetary Gearbox
Assembly from Step 27 Carefully add the 20:1 MAXPlanetary Gearbox to the MAXSpline Bearing Block assembly. As you pass the output through, add a 16T Sprocket and a 1/4in spacer before the hex shaft reaches the bearing.
Set this aside, we recommend standing the assembly up on the back end of the motor.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 35.5in
8 - MAXTube Internal Spacer - 2x1 Light
Add two MAXTube Internal Spacers to the MAXTube, they should align with the 2nd, 6th, 30th, 34th, 59th, 60th,61st, and 67th holes from the factory edge.
Get:
2 - #10-32 Button Head Screws x 2-3/4in
2 - #10 Spacer - 3/4in
MAXSpline Bearing Block +MAXPlanetary Gearbox Assembly
Attach the MAXSpline Bearing Block assembly to the MAXTube using the spacers and screws. The screws will pass through the MAXTube internal spacers in the 30th and 24th holes, as well as both bearing block plates and the #10 spacers between them before threading into the MAXPlanetary Gearbox’s output.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 12.5in
2 - MAXTube Endcap 2x1
Insert one MAXTube endcap into each end of the 12.5in piece of MAXTube.
Get:
16 - #10-32 Button Head Screws x 3/8in
Secure both endcaps with 8 screws each.
Get:
3- #10-32 Button Head Screws x 1-1/2in
Attach the shorter section of MAXTube to the 35.5in long section using screws through the 59th, 60th, and 61st holes from the factory edge.
Ensure that the screws pass through the MAXTube Internal Supports properly.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 35.5in
6 - MAXTube Internal Spacer - 2x1 Light
Add two MAXTube Internal Spacers to the MAXTube, they should align with the 2nd, 6th, 59th, 60th, 61st, and 67th holes from the factory edge.
Get:
3- #10-32 Button Head Screws x 1-1/2in
Attach the 35.5in long MAXTube piece to the rest of the assembly using screws through the 59th, 60th, and 61st holes from the factory edge.
Ensure that the screws pass through the MAXTube Internal Supports properly.
Get:
2 - 3/8in Nut Strip - 5pos
3- #10-32 Button Head Screws x 1-1/2in
Add one nut strip to each leg of the assembly that has just been finished. Position them one hole away from the factory edge on the 1in face where the left leg is empty.
Note: The screws will pass through the MAXTube Internal Supports
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 12.5in
2 - MAXTube Endcap 2x1
16 - #10-32 Button Head Screws x 3/8in
Insert one MAXTube endcap into each end of the 12.5in piece of MAXTube and secure with screws.
Get:
8 - #10-32 Button Head Screws x 1/2in
2 - MAXLift End-Mount Bearing Block
Mount two MAXLift Bearing Blocks to the MAXTube as shown using three screws each. The bearings will be facing away from the MAXTube.
Get:
6 - #10-32 Button Head Screws x 1/2in
Attach the 12.5in cross bar to the legs of the MAXLift last used in step 38 using 3 screws each.
Get:
2 - MAXLift End-Mount Bearing Block - rollers
If the rollers are not attached to your MAXLift Endmount Bearing Blocks, attach them now.
Get:
Both Assemblies (Static Stage and Single Stage)
Slide the Single Stage, the smaller stage, into the Static Stage, the bigger stage.
Note: Ensure that the MAXLift Bearing Blocks allow for smooth rolling during this step!
Get:
4 - 1/2in by 1/2in MAXTube - Cut to 26.5in
4 - 3/8in Nut Strip - 5pos
Insert one nut strip into each end of the MAXTube. Secure through the 3rd and 5th holes from the edge with screws at a perpendicular angle relative to each other.
Make two of these.
Get:
4 - #10-32 Ball Joint Rod End - Right-hand Threaded
Twist in one Ball Joint Rod End to each nut strip. At this time, screw them in all the way and hand tight so that they can be adjusted for length later.
Get:
1 - #10-32 Button Head Screws x 1-1/2in
2 - #10-32 Low Profile Nylon Lock Nut
Attach the 26.5in support rod to the 2x1 MAXTube as shown by passing a 1-3/4in Screw through the MAXTube with Internal Support and adding a nylon lock nut tightened to be flush with the 2x1 MAXTube. Then add the ball joint rod end and one more nylon lock nut to secure the support.
Get:
1 - #10-32 Button Head Screws x 1-1/2in
2 - #10-32 Low Profile Nylon Lock Nut
Repeat the previous steps on the other side of the MAXLift with the 2nd support rod.
Get:
4 - 1/2in by 1/2in MAXTube - Cut to 32.5in
4 - 3/8in Nut Strip - 5pos
4 - #10-32 Ball Joint Rod End - Right-hand Threaded
Insert one nut strip into each end of the MAXTube. Secure in the 3rd and 5th holes from the edge with screws at a perpendicular angle relative to each other. Then, twist in one ball joint rod end to each nut strip. At this time, screw them in all the way and hand tight so that they can be adjusted for length later.
Make two of these.
Get:
2 - #10-32 Button Head Screws x 3/4in
2 - #10 Spacer - 1/8in
Attach the 32.5in support rods as shown to the MAXLift. Place one 1/8in spacer between the ball joint end rod and the MAXTube for both supports.
Get:
2 - MAXTube Internal Support 2x1
1 - MAXTube 2x1 with Grid Pattern - cut to 15in
Insert two MAXTube Internal Supports into the MAXTube as shown.
Get:
1 - 15in MAXTube from last step
2 -MAXSpline Bracket - MAX Pattern T
2 - #10-32 Button Head x 1-1/2in screws
2 - #10-32 Low Profile Nylon Lock Nut
Attach two MAXspline brackets to 15in MAXTube as shown.
Get:
1 - 7in MAXTube 2x1 with MAX Pattern
3 - #10-32 Button Head x 1-1/2in screws
3 - #10-32 Low Profile Nylon Lock Nut
Attach the 7in MAXTube as shown.
Get:
1 - MAXTube 2x1 with Grid Pattern - cut to 15in
2 - MAXTube Internal Support 2x1
2 - RT25 Pulley - 1/2in Hex - 16T
1 - RT25 Belt - 1/2in Width - 80T
Insert the two MAXTube internal supports as shown. Slide the two pulleys with the belt into the MAXTube. Take care to ensure they do not fall out before securing them in future steps.
Get:
1 - 15in MAXTube 2x1 with MAX Pattern
2 -MAXSpline Bracket - MAX Pattern T
2 - #10-32 Button Head x 1-1/2in screws
2 - #10-32 Low Profile Nylon Lock Nut
Attach two MAXspline brackets to 15in MAXTube as shown, the belt should go around the left screw.
Get:
2 - MAX Pattern Plates - 3 Pos
4 - #10-32 Button Head x 3/8in screws
2 - #10 Standoff - 3/4in
Attach the plates as shown.
Get:
2 - RT25 Pulley - 1/2in Hex - 16T
1 - RT25 Belt - 1/2in Width - 48T
4 - #10 Standoff - 3/4in
8 - #10-32 Button Head x 3/8in screws
Wrap the belt around both pulleys, then install four standoffs as shown. Take care to ensure they do not fall out before securing them in future steps.
Get:
2 - MAXSpline Spacer - 1/8in
6 - Flanged Bearing for 1/2in Rounded Hex
2 - 1/2in Rounded Hex Shaft - 12in tapped
1 - 1/2in Rounded Hex Shaft - 2in tapped
2 - Shaft End Screws
Insert six bearings into the MAX plates and MAXTube, with MAXSpline spacers behind the bearings in the MAXPlates as shown. Slide the hex shafts into the bearings, with the 2in shaft in the middle bearings as shown. Secure the top shaft with a shaft end cap screw then ass a end shaft screw on the inside of the 2in hex shaft.
Get:
3 - MAXHub - 1/2in Hex - Plastic
6 - 3in - MAXSpline - Medium (Dark Gray) - Compliant Wheel
6 - #10-32 Socket Head Screw x 3/4in
Insert two MAXHubs into a compliant wheel and secure the hubs with two socket head screws. Assemble three of these wheels with hubs.
Get:
4 - 1/2in Hex Spacers - 1/2in
9 - 1/2in Hex Spacers - 1/4in
8 - 2in - 1/2in Hex - Medium (Dark Gray) - Compliant Wheels
3 - 3in Compliant Wheels from the previous step
2 - 20DP Gear - 1/2in Hex - 50T
2 - Shaft End Screws
On the top shaft slide on two 1/2in hex shaft spacers, then slide on an alternating 1/4in spacer and compliant wheel until you have eight wheels and nine 1/4in spacers, then add two more 1/2in spacers. On the middle shaft slide on the 50T gear and a 1/8in spacer then a shaft end screw. On the left side of the bottom shaft, slide on a 50t gear and a shaft end screw. On the right side slide on three 1/2in hex spacers, a 1/8in spacer, then alternate a 3in compliant wheel with two 1/2in spacers ending with an additional 1/2in spacer as shown.
Get:
1 - 3:1 MAXPlanetary System with a NEO Brushless V1.1 and a 1-3/4in output
Assemble a 3:1 MAXPlanetary System with a NEO Brushless V1.1 and a 2in output.
Get:
1 - 3:1 MAXPlanetary System with a NEO Brushless V1.1 and a 1-3/4in output
1 - 1/2in Rounded Hex Bearing
2 - #10 Spacer - 3/4in
2 - Button Head Hex Drive Screw #10-32 x 1-1/2in
1 - 2 Piece 1/2" Hex Plastic Shaft Collar
Mount the MAXPlanetary system to the MAXTube with spacers on the inside of the MAXTube and the output shaft through the RT25 pulley. Slide a 1/2in bearing onto the output shaft and then secure with a 1/2in hex shaft collar.
Get:
1 - MAXSpline shaft cut to 12-1/2in
Slide the MAXSpline through MAXTube until you have 7/8in sticking through the MAXTube as shown.
Get:
1 - MAXSpline shaft collar
1 - #25 Billet Sprocket - 48T
6 - #10-32 Button Head Hex Drive Screw x 2in
6 - #10-32 Low Profile Nylon Lock Nut
Slide the sprocket onto the MAXSpline then install the MAXSpline shaft collar. Secure the sprocket to the shaft collar with the screws and nuts as shown.
Get:
1 - MAXTube from Step 3
2 - Flanged Bearing for 1/2in Rounded Hex
Slide the bearings onto the shafts with wheels then slide the MAXTube assembly from Step 3 onto the MAXSpline and 1/2in hex, take care to ensure the whole assembly is square. (The internal corners are vertically and horizontally even for something to be square and exhibit 90-degree angles)
Get:
1 - MAXSpline shaft collar
6 - #10-32 Button Head Hex Drive Screw x 2in
6 - #10-32 Low Profile Nylon Lock Nut
Install the MAXSpline shaft collar with the screws and nuts as shown.
Get:
1 - 1/2in Rounded Hex Shaft cut to 12-1/2in tapped
2 - 1/2in Rounded Hex Bearing - Flanged - 1in OD
Slide the 1/2in hex shaft through the MAXSpline, then bearings onto the ends of the 1/2in hex shaft.
Get:
1 - Intake Hood cut from Polycarbonate Sheet
You can download a copy of the DXF files for the Coral Hood pieces for laser cutting or CNC routing here:
Part 1 (Sides)
Part 2 (Top and Bottom)
Get:
2 - MAXTube Internal Support 2x1
1 - MAXTube 2x1 with MAX Pattern - cut to 9in
Insert two MAXTube Internal Supports into each end of the MAXTube pieces. Take care to ensure they do not fall out before securing them in the next step.
Get:
1 - MAXPlanetary System 45:1 with 2.5in tapped output shaft
1 - 1/2in Rounded Hex Bearing
2 - #10-32 Button Head Screws x 1.5in
Attach the MAXPlanetary System as shown. Insert a 1/2 bearing on the opposite side of the MAXPlanetary System to support the output shaft.
Get:
1 - 20DP Gear - 1/2in Hex - 20T
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - 1/2in Hex Shaft Spacer - 1/8in
2 - 1/2in Hex Shaft Spacer - 1/16in
1 - #10-32 Shaft End Screw
Slide onto the output shaft, in this order, a 1/16in spacer, a 20T gear, a 1/4in spacer, a 1/8in spacer, a 1/16in spacer, and a shaft end screw.
Get:
1 - 1/2in Rounded Hex Shaft - 2.5in tapped
2 - 1/2in Rounded Hex Bearing
1 - #10-32 Shaft End Screw
1 - 1/2in Hex Shaft Spacer - 1/16in
Insert two 1/2in bearings into the MAXTube as shown. Slide a 1/6in spacer onto left side as shown and secure with a shaft end screw.
Get:
1 - MAXSpline Shaft cut to 1.125in
1 - MAXSpline Shaft Endcap - 1/2in Hex
1 - Bushing - Plastic - 13.75mm ID - 1in OD
Slide onto the hex shaft as shown in this order, a MAXSpline Shaft Endcap, a 1.125 cut section MAXSpline Shaft, and a 1in plastic bushing.
Get:
1 - 20DP Gear - MAXSpline - 60T
1 - MAXSpline Spacer - 1/4in
1 - MAXSpline Spacer - 1/16in
Slide onto the output shaft, in this order, a 60T gear, a 1/4in spacer, a 1/16in spacer.
Get:
1 - MAXSpline Pillow Block
1 - MAXHub - Structural
1 - #10-32 Shaft End Screw
Slide onto the output shaft a MAXSpline pillow block and then insert a MAXHub into the pillow block. Secure the shaft with a shaft end screw.
Get:
1 - MAXTube 2x1 with MAX Pattern - cut to 9in
1 - 1/2in Round Hex Shaft - 2in Tapped
1 - 1/2in Hex Shaft Spacer - 1/4in
1 - 1/2in Hex Shaft Spacer - 1/8in
1 - Bushing - Plastic - 13.75mm ID - 1in OD
Insert two plastic bushings into each side of the MAXTube. Slide a 2in hex shaft through the bushings then slide a 1/4in spacer onto the left side as shown and a 1/8in spacer and shaft end screw on the right.
Get:
1 - MAXSpline Pillow Block
1 - MAXHub - Structural
1 - MAXHub - 1/2in Hex - Aluminum
1 - #10-32 Button Head Screws x 3/4in
#10-32 Low Profile Nylon Lock Nut
Insert a structural and a 1/2in hex MAXHub into a MAXSpline Pillow Block and secure with a 3/4in screw and lock nut as shown.
Get:
1 - #10-32 Shaft End Screw
Slide the pillow block onto the 1/2in hex shaft and secure it with a shaft end screw.
Get:
1 - MAXSpline cut to 17-3/4in
Slide the two MAXTube sections onto a 17-3/4in cut MAXSpline shaft. Leave 1-1/2in on the left side as shown and 2-1/8in on the right side as shown. Note: Significant force may be needed
Get:
1 - MAXTube cut to 15in
2 - MAXSpline Shaft Collar
Slide the MAXTube section onto the shaft from the previous step. Secure the MAXTube with shaft collars as shown.
Get:
2 - MAXHubs - 1/2in Hex - Plastic
1 - #10-32 Button Head Screws x 3/4in
Slide the MAXHubs into the MAXTube as shown. Secure the MAXHubs with a screw.
Get:
1 - MAXSpline cut to 14-3/4in
1 - 1/2in Rounded Hex Shaft cut to 16-3/4in
2 - 1/2in Rounded Hex Bearing - Flanged - 1in OD
Slide the section MAXSpline shaft onto the hex shaft, then slide the two bearings onto hex shaft and into the MAXSpline as shown.
Get:
4 - Grip Wheel - 4in - MAXSpline - Hard
1 - RT25 Plastic Pulley - MAXSpline - 24T
Slide onto the MAXSpline the Grip Wheels and pulley as shown.
Get:
1 - MAXTube with MAX Pattern - 15in
1 - MAXTube Internal Spacer
1 - MAXHub - Structural
1 - MAXHub - 1/2in Hex - Aluminum
1 - #10-32 Button Head Screws x 3/4in
Slide into the MAXTube the internal spacer. Insert the MAXHubs and secure them with a screw as shown.
Get:
1 - MAXTube from the previous step
1 - RT25 Belt - 1/2in Width - 88T
1 - MAXSpline Spacer - 1/2in
1 - MAXSpline Spacer - 1/8in
1 - MAXSpline Shaft Collar
1 - Shaft End Screw
Wrap a 88 tooth belt around the pulley on the MAXSpline. Slide onto the right MAXSpline the 1/8in and 1/2in spacer as shown. Slide the MAXTube from the previous step onto the MAXSpline and 1/2in hex as shown then secure the 1/2in hex shaft with a shaft end screw and the MAXSpline with a MAXSpline Shaft Collar.
Get:
1 - 3:1 MAXPlanetary System with a NEO Vortex and a 1-3/4in output
Assemble a 3:1 MAXPlanetary System with a NEO Vortex and a 1-3/4in output.
Get:
1 - MAXSpline Bearing Block
1 - 1/2in Hex Spacer - 1/8in
1 - 1/2in Hex Spacer - 1/2in
2 - #10-32 Button Head Screws x 5/8in
1 - RT25 Pulley - 1/2in Hex - 16T
Slide the 1/8in and 1/2in spacers onto the output shaft. Install the bearing block onto the MAXPlanetary Output with two screws. Slide the 16T pulley onto the output shaft.
Get:
2 - MAXSpline Bearing Blocks
1 - 1/2in Rounded Hex Bearing
4 - #10-32 Button Head Screws x 2-1/2in
4 - #10 Spacers - 3/4in
Wrap the 88 tooth belt around the 16T pulley. Insert a 1/2in bearing into a bearing block then use the two bearing blocks and the MAXPlanetary system from the last step to to mount the MAXPlanetary System and create tension on the belt.
Get:
1 - 1/2in x 1/2in MAXTube cut to 4in
1 - #10 Spacer - 1/4in
1 - #10 Socket Head Screw x 2-1/2in
1 - #10-32 Low Profile Nylon Lock Nut
Secure the 1/2in MAXTube through the MAXSpline Spacer and MAXTube as shown.
Get:
1 - 1/2in x 1/2in MAXTube cut to 9-1/2in
1 - #10 Socket Head Screw x 1-1/2in
2 - #10-32 Low Profile Nylon Lock Nut
Secure the 1/2in MAXTube with two nuts as shown, leave this loose enough for the MAXTube to roate around the screw.
Get:
1 - 3/8in Nut Strip - 5 Pos
3 - #10-32 Button Head Screws x 1/2in
1 - #10-32 Ball Joint Rod End - Left-hand Threaded
Secure the nut strip in MAXTube with three screws as shown. Screw the tie rod end in as shown.
Get:
Single Stage Elevator Assembly
Drivetrain Assembly
4 - #10-32 Button Head Hex Drive Screw x 2-1/2in
4 - #10-32 Button Head Hex Drive Screw x 3/4in
4 - #10 Spacers - 1/8in
Secure the Elevator to the Drivetrain with four 2-1/2in screws from the underside of the drivetrain as shown. Secure the bracing to the endcaps on the drivetrain. You should need to adjust the tie rod ends until the bracing is rigid, this may take two people to "pull" on the bracing to provide tension. The Elevator should be completely rigid with no movement independent from the drivetrain. Note: The bracing on the backside of the Starterbot do cross and attach to opposite sides on the endcaps, see the second image.
Lift the single stage till you have at least ten inches showing, insert a bolt or metal screwdriver that is at least 2-1/2in in length through the static stage and through the single stage to keep the Elevator lifted. Note: DO NOT use Zip Ties to hold up the elevator.
Get:
Intake Assembly
2 - #10-32 Button Head Hex Drive Screw x 1-1/2in
2 - 1/2in Hex Shaft Spacer - 1/16in
Slide a 1/16in spacer onto the 1/2in hex shaft of the intake then mount the intake to the elevator through the holes with the internal support as shown.
Get:
1 - #25 Chain that is 163links with a turnbuckle
Wrap the chain around the sprocket on the Intake and the MAXPlanetary system on the Elevator. The turnbuckle should be near the sprocket with the Intake down. Adjust the location of the turnbuckle if it makes contact with the sprocket on the intake or MAXPlanetary.
Get:
2 - #25 Chain that is 287 links with a turnbuckle
Wrap the chain around the 16T sprockets on the Elevator and the 16T sprockets on the Drivetrain. The turnbuckle should be near the sprockets on the Elevator with the Elevator down. Adjust the location of the turnbuckle if it makes contact with the sprockets on the Elevator or Drivetrain shaft.
Get:
10 - M3 Hex Cap Screws x 20mm
10 - M3 Nyloc Nuts
2 - Chain Adapter Blocks
6 - #10-32 Button Head Hex Drive Screw x 1/2in
Attach a Chain Adapter Block to both Elevator chains with the M3 screws and nuts and then attach the adapters to the nut strips on the elevator with the #10-32 screws as shown.
Get:
4 - #10-32 Button Head Hex Drive Screw x 2-1/2in
4 - #10-32 Low Profile Nylon Lock Nut
Attach the Ball Intake to the Drivetrain using the screws and nuts as shown.
Get:
1 - #10-32 Button Head Hex Drive Screw x 1-3/4in
1 - #10-32 Low Profile Nylon Lock Nut
1 - #10 Spacers - 1/4in
Lift the Elevator, then attach the Ball Intake brace to the Elevator with the nut and spacer on the outside of the elevator.
Get:
1 - Zip Tie
1 - Surgical Tubing
Make a loop with a Zip Tie at the corner of the bracing on the Ball Intake, then make a loop of surgical tubing through the Zip Tie loop and the nut strip on the ELevator bracing as shown. This should be tight enough to pull the Ball Intake but not snap when the intake is deployed.
Get:
All Necessary Electronics
Install your electronics in your preferred locations, we have suggested
You are done!
Get:
4 - 1in Bracket - 90deg - Sharp Interior
1 - MAXTube - 2x1 with Grid Pattern - Cut to 21in
12 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the Brackets to the 21in MAXTube as shown using 3/16in rivets.
Get:
1 - MAXTube - 2x1 with MAX Pattern - Cut to 11in
12 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 11in MAXTube to the Brackets as shown using 3/16in rivets.
Get:
4 - 1in Bracket - 90deg
1 - MAXTube - 2x1 with Grid Pattern - Cut to 19in
24 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 19in MAXTube with Grid pattern to the MAXTube with MAX pattern with the Brackets as shown using 3/16in rivets.
Get:
4 - MAXTube Endcaps 1x1
2 - MAXTube - 1x1 - Cut to 2in
12 - Button Head Hex Drive Screw #10-32 x 3/8in
Attach the Endcaps to the MAXTube with the screws as shown. Do this twice so that you have two separate pieces.
Get:
2 - 2in MAXTube with Endcaps from previous step.
4 - Button Head Hex Drive Screw #10-32 x 1-1/4in
Secure the MAXTube with Endcaps from previous step to the 21in MAXTube with Grid Pattern using screws as shown.
Get:
2 - MAXSpline Bracket - Stacked
12 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the MAXSpline Bracket as shown using 3/16in rivets.
Get:
10 - Flanged Bearing for 1/2in Rounded Hex
Insert the Bearings into the MAXSpline Bore as shown.
Get:
1 - 1/2in Rounded Hex Shaft Cut to 22.368in
2 - 1 Piece 1/2in Hex Plastic Shaft Collar
1 - 20DP Gear - 1/2in Hex - 52T
2 - 20DP Gear - 1/2in Rounded Hex - 16T
2 - #10-32 Shaft End Screw
Insert the the 1/2in Hex Shaft as shown, with the 52T gear and shaft collars on the inside and the 16T gears and end screws on the outside.
Get:
1 - 1/2in Rounded Hex Shaft - 3.0in - Tapped
1 - MAXPlanetary 1/2in Hex Socket Output
1 - #10-32 Shaft End Screw
1 - 20DP Gear - 1/2in Hex - 28T
2 - 1/2in Hex Shaft Spacer - 1/4in
1 - 1/2in Hex Shaft Spacer - 1/8in
1 - 1/2in Hex Shaft Spacer - 1/16in
Insert the the 1/2in Hex Shaft as shown, on the outside end(left side of image) slide a 1/4in & 1/8in Spacer, securing with a Shaft End Screw. On the inside(right side of image) slide on the 28T Gear, 1/16 & 1/4 Spacer, securing the end of the shaft with the MAXPlanetary 1/2in Hex Socket Output
Get:
1 - MAXPlanetary system with 2 5:1 stages.
2 - Button Head Hex Drive Screw #10-32 x 2-1/2in
2 - 1in #10 Spacers
2 - 3/4in #10 Spacers
2 - 1/8in #10 Spacers
Attach the MAXPlanetary system to the 1/2in Hex Socket Output using the MAXPlanetary hardware. Secure the system to the MAXSpline Brackets with a 2-1/2in screw, a 1in spacer between the brackets, and the 3/4in & 1/8in spacers between the brackets and the MAXPlanetary system.
Get:
2- Dead Axle Tube - 3/4in - cut to 9.82in
2 - Tube Nut for 3/4in Dead Axle Tube, RH Thread
2 - Tube Nut for 3/4in Dead Axle Tube, LH Thread
2 - #10-32 Ball Joint Rod End - Right-hand Threaded
2 - #10-32 Ball Joint Rod End - Left-hand Threaded
4 - #10-32 Jam Nut
4 - Oversize #10 Washer
Press a RH Thread Tube Nut into the Dead Axle Tube and then the LH Thread Tube Nut into the other end. You may need to use a mallet to hammer in the Tube Nuts. Place a Washer over the tube nut then screw in a appropriately threaded Jam Nut and Ball Joint Rod End. Do this twice so that you have two Turnbuckle Braces.
Get:
2- Turnbuckle Braces from previous Step
2 - Button Head Hex Drive Screw #10-32 x 2in
2 - 1/4in #10 Spacers
2 - #10-32 Low Profile Nylon Lock Nut
Secure the Turnbuckle Braces to the MAXTube as shown.
Get:
1 - MAXTube, 1x1 - cut to 18in
1 - MAX Pattern Plate - 1-Pos (2.48in)
1 - 20DP Gear - 1/2in Hex - 64T
2 - Button Head Hex Drive Screw #10-32 x 1-1/2in
2 - #10-32 Low Profile Nylon Lock Nut
Attach the MAX Pattern Plate and the 64T Gear to the end of the MAXTube with two screws and nuts. Please note: the MAX Plate is the gear and MAXTube.
Get:
1 - 1in Pivot Joint
4 - Button Head Hex Drive Screw #10-32 x 3/8in
On the other end of the of the same MAXTube from the previous step attach a 1in Pivot Joint with four screws
Get:
2 - 1in Bracket - 90deg
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 90deg Brackets as shown using 3/16in rivets. The Bracket and first rivet start on the 14th hole from the Pivot Joint. Put this to the side, you will use it in a later step.
Get:
1 - MAXTube, 1x1 - cut to 18in
1 - MAX Pattern Plate - 1-Pos (2.48in)
1 - 20DP Gear - 1/2in Hex - 64T
2 - Button Head Hex Drive Screw #10-32 x 1-1/2in
2 - #10-32 Low Profile Nylon Lock Nut
Attach the MAX Pattern Plate and the 64T Gear to the end of the MAXTube with two screws and nuts. Please note: the MAX Plate is the gear and MAXTube.
Get:
1 - 1in Pivot Joint
4 - Button Head Hex Drive Screw #10-32 x 3/8in
On the other end of the of the same MAXTube from the previous step attach a 1in Pivot Joint with four screws
Get:
2 - 1in Bracket - 90deg
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 90deg Brackets as shown using 3/16in rivets. The Bracket and first rivet start on the 14th hole from the Pivot Joint. Put this to the side, you will use it in a later step.
Get:
1 - 1/2in Rounded Hex Shaft Cut to 22.5in - Threaded
2 - 1 Piece 1/2in Hex Plastic Shaft Collar
2 - 1/2in Hex Shaft Spacer - 1/2in
Insert the the 1/2in Hex Shaft as shown, with the both 1/2in spacers on the right side. Securing the shaft with Shaft Collars.
Get:
2 - The arms you set aside in previous steps
2 - Button Head Hex Drive Screw #10-32 x 1-1/2in
2 - 1/2in Hex Shaft Spacer - 1/8in
Attach the two arms from the previous steps to the 1/2in Hex Shaft as shown, with a 1/8in spacer and screw on each side.
Get:
1 - MAXTube, 1x1 cut to 22.5in
12 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the MAXTube to90deg Brackets as shown using 3/16in rivets. Set this aside for final assembly.
Get:
1 - MAXTube, 1x1 - cut to 13in
1 - 1in Pivot Joint
4 - Button Head Hex Drive Screw #10-32 x 3/8in
Attach a 1in Pivot Joint with four screws.
Get:
2 - 1in Bracket - 90deg
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 90deg Brackets as shown using 3/16in rivets.
Get:
1 - MAXTube, 1x1 - cut to 3.5in
4 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the MAXTube to the 90deg Brackets as shown using 3/16in rivets.
Get:
1 - 1in Pivot Joint
2 - Button Head Hex Drive Screw #10-32 x 3/8in
2 - Button Head Hex Drive Screw #10-32 x 1/2in
Attach a 1in Pivot Joint with the two 1/2in screws through the Bracket and MAXTube and the 3/8in screw through just the MAXTube.
Get:
2 - 1in Bracket - T
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 1in Brackets as shown using 3/16in rivets. Put this to the side, you will use it in a later step.
Get:
1 - MAXTube, 1x1 - cut to 13in
1 - 1in Pivot Joint
4 - Button Head Hex Drive Screw #10-32 x 3/8in
Attach a 1in Pivot Joint with four screws.
Get:
2 - 1in Bracket - 90deg
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 90deg Brackets as shown using 3/16in rivets.
Get:
1 - MAXTube, 1x1 - cut to 3.5in
4 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the MAXTube to the 90deg Brackets as shown using 3/16in rivets.
Get:
1 - 1in Pivot Joint
2 - Button Head Hex Drive Screw #10-32 x 3/8in
2 - Button Head Hex Drive Screw #10-32 x 1/2in
Attach a 1in Pivot Joint with the two 1/2in screws through the Bracket and MAXTube and the 3/8in screw through just the MAXTube.
Get:
2 - 1in Bracket - T
6 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 1in Brackets as shown using 3/16in rivets. Put this to the side, you will use it in a later step.
Get:
1 - MAXSpline Shaft - cut to 22in
2 - MAXTube, 2x1 with MAX Pattern, 3in Long
1 - MAXSpline Shaft Collar - 2-Piece - Aluminum
2 - Button Head Hex Drive Screw #10-32 x 2in
2 - #10-32 Low Profile Nylon Lock Nut
Slide the MAXTube and Shaft Collar onto the MAXSpline Shaft as shown. Attach the shaft collar to a MAXTube using the Button Head Screws and Lock Nuts. Please note: do not tighten the shaft collar yet, you will need to adjust these MAXTubes when mounting to your chosen drivetrain.
Get:
1 - 1/2in Rounded Hex Shaft Cut to 23.5in - Threaded
2 - MAXSpline Shaft Endcap - 1/2in Hex - Aluminum
2 - 1#10-32 Shaft End Screw
2 - 1/2in Hex Shaft Spacer - 1/8in
Insert the the 1/2in Hex Shaft as shown, with the both 1/2 spacers on the right side. Securing the shaft with Shaft Collars.
Get:
2 - The arms you set aside in previous steps
2 - #10-32 Shaft End Screw
2 - 1/2in Hex Shaft Spacer - 1/8in
Attach the two arms from the previous steps to the 1/2in Hex Shaft as shown, with a 1/8in spacer and screw on each side.
Get:
1 - MAXTube, 1x1 cut to 22.5in
12 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the MAXTube to the T Brackets as shown using 3/16in rivets. Set this aside for final assembly.
Get:
2 - MAXTube - 1x1 cut to 20in
4 - MAXTube Endcap - 1x1
12 - Button Head Hex Drive Screw #10-32 x 3/8in
Attach the the end caps to both ends of MAXTube. Make sure the side without a screw is the same with both Endcaps. Do this twice so that you have two separate pieces.
Get:
1 - MAXTube - 2x1 with MAX Pattern cut to 25in
2 - MAXTube Internal Support- 2x1
2 - Button Head Hex Drive Screw #10-32 x 1-1/2in
Insert the Internal Supports into the MAXTube, hold them in place with the screws. Do this twice so that you have two separate pieces.
Get:
2 - MAXTube - 1x1 From Pevious Steps
2 - MAXTube - 2x1 with MAX Pattern From previous Step
Screw these together with the Button Head Hex Drive Screw #10-32 x 1-1/2in from the previous step. Make sure the side of the 1x1 MAXTube without a screw is flush with the 2x1 MAXTube.
Get:
4 - 1in Bracket - T
24 - 3/16in Rivet - 0.126-0.250in Grip Length
Attach the 1in T Brackets as shown using 3/16in rivets.
Get:
2 - 1in Bracket - 90deg
12 - 3/16in Rivet - 0.126-0.250in Grip Length
1 - MAXTube - 1x1 cut to 5.25in
Attach the 90deg Brackets and MAXTube as shown using 3/16in rivets. Put this to the side, you will use it in a later step.
Get:
1 - NEO Brushless Motor
1 - One Half MAXSpline Bearing Block - 2x1
2 - Button Head Hex Drive Screw #10-32 x 3/8in
Attach the Half MAXSpline Bearing Block to the NEO using the Button head screws.
Get:
2 - 8mm Shaft Spacer, 1/8in Long
1 - RT25 Pulley - 8mm Bore - 12T - Single
1 - Retaining Clip - 8mm
1 - 2mm x 2mm, 20mm (or other appropriate length) keyway
Slide two spacers, install key into keyway, and the the 12T pulley onto the NEO Shaft, secure the pulley with a retaining clip. Put this to the side, you will use it in a later step.
Get:
1 - MAXTube, 2x1 with MAX Pattern 7in
1 - RT25 Belt - 1/2in Width - 48 Tooth
1 - RT25 Pulley - 1/2in Hex - 16T - Single
Put the belt around the pulley, then slip both into the MAXTube.
Get:
1 - NEO from previous steps
Insert the NEO's shaft through the MAX Spline bore and wrap the belt around the pulley.
Get:
1 - Other one half MAXSpline Bearing Block - 2x1
4 - Button Head Hex Drive Screw #10-32 x 1-1/2in
Attach the other half of the MAXSpline Bearing Block to the NEO using the Button head screws. Please note: do not tighten these screws as the motor will need to be adjusted for tension later.
Get:
2 - Flanged Bearing for 1/2in Rounded Hex
2 - MAXSpline Spacer, 1/8in
Press a Bearing into the MAX Spline Bore with a 1/8in spacer in-between. Do this on both sides.
Get:
1 - Button Head Hex Drive Screw #10-32 x 2in
1 - #10-32 Low Profile Nylon Lock Nut
Insert a screw through the MAXTube as shown, secure it with a lock nut. Put this to the side, you will use it in a later step.
Get:
12 - Flanged Bearing for 1/2in Rounded Hex
Insert the Bearings into the MAXSpline Bore as shown.
Get:
4 - MAXHub - 1/2in Hex - Plastic - 2 Pack
4 - Button Head Hex Drive Screw #10-32 x 1-1/4in
4 - Socket Head Screw #10-32 x1in
4 - 1/2in Rounded Hex Shaft - Cut to 1.75in
4 - Button Head Hex Drive Screw #10-32 x 1/2in
4 - 1/2in Hex Shaft Spacer - 1/8in
Install the MAXHubs with a Socket Head screw and a 1-1/4in button head screw. The socket head should be one the outside half of the Hub for clearance. Insert the Hex Shaft, securing with the 1/2in button head screw. Slide the 1/8in spacer onto the Hex shaft.
Get:
1 - 1/2in Rounded Hex Shaft - Cut to 22.125in
1 - 1/2in Rounded Hex Shaft - Cut to 22.875in
2 - RT25 Pulley - 1/2in Hex - 16T - Single
1 - RT25 Belt - 1/2in Width - 64 Tooth
16 - 2in Grip Wheel - 1/2in Hex Bore - Soft
4 - 1/2in Hex Plastic Shaft Collar
3 - #10-32 Shaft End Screw
Insert the 22.125in Hex Shaft through the upper bearing on the left side frame and the 22.875in through the middle bearing on the same side. Slide onto these shafts the RT25 Pulleys and Belt at the same time for tension. Secure the pulleys with Shaft Collars and then slide on 8 Grip wheels on each shaft. Center the upper shaft an secure it with a shaft collar on the right, then both ends with Shaft End Screws. Slide onto the Middle shaft, a shaft collar and the free floating gearbox assembled in previous steps. Slide the shaft to leave the excess on left side of the frame as shown. Screw a Shaft End Screw into the right side of the shaft. Please Note: Adjust MAXSpline Bearing Block on the free floating gearbox to create tension on the the belt. You may also choose to secure the gearbox to the frame of the intake with the fastener of your choice. i.e. zip ties. Please Note: A little bit of tape in-between each grip wheel will keep them from sliding on the shaft.
Get:
1 - 1/2in Rounded Hex Shaft - Cut to 22.875in
2 - RT25 Pulley - 1/2in Hex - 16T - Single
1 - RT25 Belt - 1/2in Width - 64 Tooth
2 - 1/2in Hex Plastic Shaft Collar
8 - 2in Compliant Wheel - 1/2in Hex Bore - Soft
3 - Intake Flap - 1/2in Hex - Soft
3 - #10-32 Shaft End Screw
Insert the 22.875in Hex Shaft through the lower bearing on the left side frame. Slide onto the shaft the Compliant wheels, intake flaps, and shaft collars as shown. Slide the shaft to leave the excess on left side of the frame as shown. Screw a Shaft End Screw into the right side of the shaft. Slide onto excess of these shafts the RT25 Pulleys and Belt at the same time for tension securing with Shaft End Screws. Tighten all shaft collars. Please Note: A little bit of tape in-between each grip wheel will keep them from sliding on the shaft.
Get:
1 - Polycarbonate slider bed
8 - #10 Standoff - 1.75in
8 - Button Head Hex Drive Screw #10-32 x 2-1/2in
8 - Button Head Hex Drive Screw #10-32 x 1/2in
Secure the polycarbonate slider bed as shown.
Get:
1 - MAXTube, 2x1 Light with Grid Pattern - Cut to 20in
2 -MAXTube Endcap - 2x1 Light
8- Button Head Hex Drive Screw #10-32 x 3/8in
Screw the MAXTube Endcaps into the MAXtube.
Get:
2 - MAXTube, 2x1 with MAX Pattern - Cut to 11in
2 -MAXTube Internal Support - 2x1
4 - Button Head Hex Drive Screw #10-32 x 1-1/2in
Screw the 11in MAXTube into the MAXTube with Grid Pattern with the 1-1/2in screws and internal supports.
Get:
4 - MAXSpline Bracket - MAX Pattern T
24 - 3/16in Rivet - 0.126-0.250in Grip Length
Rivet the brackets as shown.
Get:
8 - Flanged Bearing for 1/2in Rounded Hex
Insert the bearings as shown
Get:
1 - NEO Brushless Motor
1 - One Half MAXSpline Bearing Block - 2x1
2 - Button Head Hex Drive Screw #10-32 x 3/8in
2 - 8mm Shaft Spacer, 1/8in Long
1 - RT25 Pulley - 8mm Bore - 12T - Single
1 - RT25 Belt - 1/2in Width - 40 Tooth
1 - Retaining Clip - 8mm
1 - 2mm x 2mm, 20mm (or other appropriate length) keyway
Attach the Half MAXSpline Bearing Block to the NEO using the Button head screws. Slide onto the shaft of the NEO both spacers, install key into keyway, the pulley with belt, and secure it with the retaining clip.
Get:
1 - One whole MAXSpline Bearing Block - 2x1
4 - Button Head Hex Drive Screw #10-32 x 3in
4 - #10 Spacer - 3/4in
4 - #10 Spacer - 1/8in
Mount the NEO using the MAXSpline Bearing Block as a clamp to the frame. Make sure to leave enough belt to wrap around it's pulley in later steps.
Get:
1 - NEO Brushless Motor
1 - One Half MAXSpline Bearing Block - 2x1
2 - Button Head Hex Drive Screw #10-32 x 3/8in
3 - 8mm Shaft Spacer, 1/8in Long
1 - RT25 Pulley - 8mm Bore - 12T - Single
1 - RT25 Belt - 1/2in Width - 72 Tooth
1 - Retaining Clip- 8mm
1 - 2mm x 2mm, 20mm (or other appropriate length) keyway
Attach the Half MAXSpline Bearing Block to the NEO using the Button head screws. Slide onto the shaft of the NEO all three spacers, install key into keyway, pulley with belt, and secure it with the retaining clip.
Get:
1 - One whole MAXSpline Bearing Block - 2x1
4 - Button Head Hex Drive Screw #10-32 x 3in
4 - #10 Spacer - 3/4in
4 - #10 Spacer - 1/8in
Mount the NEO using the MAXSpline Bearing Block as a clamp to the frame. Make sure to leave enough belt to wrap around it's pulley in later steps.
Get:
12- Grip Wheel - 3in - MAXSpline - Hard
24 - MAXHub - 1/2in Hex - Aluminum
24 - Socket Head Screw #10-32 x1-1/4in
Insert a MAXHub into both sides of a 3in Grip Wheel. Screw the hubs together with the Socket Head Screws. Please Note: Do this 12 times so that you 12 wheels with MAXHubs.
Get:
1 - 1/2in Rounded Hex Shaft - Cut to 22.375in
1 - 1/2in Hex Shaft Spacer - 1/8in
1 - 1/2in Hex Shaft Spacer - 1/16in
1 - RT25 Pulley - 1/2in Hex - 16T - Single
8 - 1/2in Hex Plastic Shaft Collar
12 - 3in Wheels with MAXHubs
2 - 1/2in Hex Shaft Spacer - 1/2in
2 - #10-32 Shaft End Screw
Insert the Hex Shaft through the upper bearing on the left side frame. Slide onto the shaft the 1/8 and 1/16 spacers, the pulley with belt wrapped around, then the shaft collars and wheels as shown. Slide both 1/2in spacers on the end through the 72T belt. Secure with Shaft End Screws. Tighten all shaft collars. Please Note: You may need to adjust the NEO up or down to get the shaft and pulley through. Then adjust it for tension.
Get:
1 - 1/2in Rounded Hex Shaft - Cut to 22.125in
1 - 1/2in Hex Shaft Spacer - 1/8in
1 - 1/2in Hex Shaft Spacer - 1/16in
1 - RT25 Pulley - 1/2in Hex - 16T - Single
8 - 1/2in Hex Plastic Shaft Collar
12 - 3in Wheels with MAXHubs
2 - #10-32 Shaft End Screw
Insert the Hex Shaft through the upper bearing on the left side frame. Slide onto the shaft the shaft collars and wheels as shown. Then the pulley with belt wrapped around and the 1/8 and 1/16 spacers. Secure with Shaft End Screws. Tighten all shaft collars. Please Note: You may need to adjust the NEO up or down to get the shaft and pulley through. Then adjust it for tension.
Get:
4 - Button Head Hex Drive Screw #10-32 x 2-1/2in
Use 2-1/2in Screws to secure the Four-Bar assembly to the Drivetrain. You will be using the 11th and 13th holes from the edge of drivetrain. Please Note: This is assembly with our MAXSwerve Drivetrain.
Get:
4 - Button Head Hex Drive Screw #10-32 x 2-1/2in
4 - #10-32 Low Profile Nylon Lock Nut
Use 2-1/2in Screws and nuts to secure the Four-Bar assembly to the Drivetrain. You will be using the 16th and 20th holes from the edge of drivetrain. Please Note: This is assembly with our MAXSwerve Drivetrain.
Get:
2 - Button Head Hex Drive Screw #10-32 x 2in
2 - #10 Spacer, 1/4in
2 - #10-32 Low Profile Nylon Lock Nut
Use 2in Screws, nuts and spacers to secure the Turnbuckle Angle Braces to the Drivetrain. The spacer should go between the Ball Joint Rod End and the frame. You will be using the 19th Please Note: This is assembly with our MAXSwerve Drivetrain.
Get:
24 - 3/16in Rivet - 0.126-0.250in Grip Length
Rivet the Launcher Assembly to the Intake Assembly as shown. Please Note: This is assembly with our MAXSwerve Drivetrain.
Get:
4 - #10-32 Shaft End Screw
Slide the Pivot Joints on the Four-Bar assembly onto the Hex Shafts and secure them with Shaft End Screw. Please Note: This is assembly with our MAXSwerve Drivetrain.
In FIRST Robotics Competition robots, drivetrains consist of all the components needed to make the robot move around the game field. Drivetrains are a crucial part of the robot and are often one of the first parts of the robot that a team begins designing and iterating upon.
Most drivetrains will use motors connected to gearboxes to transmit motion to wheels with belts or chain. Some teams will incorporate parts such as pneumatics and servos into their drivetrains as well, allowing for shifting of gears and changing what wheels are in contact with the ground at certain points in the game.
Drivetrains have various forms, each having its own pros and cons- the optimal drivetrain for a team is one that finds the correct balance of speed, maneuverability, and power to fit within that team's specific strategy.
West Coast Drive is generally characterized by having six, eight, or ten wheels that are cantilevered. Further, one wheel on each side is directly driven, while the rest are linked via chain. To help improve maneuverability, omni wheels can be used on the front or back, so wheels slide across the floor while turning. When using six or more wheels, lowering the middle wheel of the drivetrain can cause less friction because not all wheels are touching the floor at one time.
See REV's West Coast Drive built using ION products here:
Swerve drivetrain uses standard wheels mounted on their own pivoting mechanisms. Most swerve drivetrains require two motors per wheel; one to rotate the wheel, and one to control the direction the wheel points. Your robot can move in any direction because the drive wheels pivot without changing the orientation of the drivetrain, but this type of drivetrain is very technically complex. There are multiple types of swerve drive, including crab drive and 2+2 configuration.
Swerve Drives offer a huge increase in maneuverability, at the cost of increased build complexity and increased resource costs, including weight, space, capital, and time.
See REV's Swerve Drive built using ION products, including the MAXSwerve Module here:
Some other common drivetrains used in FIRST include:
Two Wheel Drive (also known as "casterbot")
Four Wheel Drive
Six Wheel Drive variations that are not specifically West Coast Drive
Car Drive
H-Drive
Holonomic Drive
Mecanum Drive
All of these systems have their own advantages and disadvantages that should be discussed by your team. This is by no means a comprehensive list, either!
As teams learn, adapt, and iterate on each year's unique challenges, new drivetrains are created annually to meet the criteria needed to succeed and make it all the way to Einstein!
Meet the 2023 REV ION FRC Starter Bot! Using all REV ION parts, the Starter Bot is the culmination of analyzing the game, prototyping, and technical documentation. The 2023 REV ION FRC Starter Bot is designed to give teams a starting point for building their robot, while leaving room for iteration, revision, and adaptation to the game’s challenges.
Assembly Instructions
and
Teams will need to cut and tap some pieces of structural tubing in order to build the 2023 REV ION FRC Starter Bot. The following sections detail the quantity and length needed for each type of extrusion.
Every piece of structural tubing needs to start with a hole 1/2in (or slightly less) from the end where the length measurement is taken FROM.
2x1 Light MAXTube with Grid Pattern:
1x 22-1/2in (Tower Bottom Crossbar)
2x 2-1/2in (Tower Riser)
3/4in Dead Axle Tube:
2x 26-3/4in (Tower Brace)
2x1 Light MAXTube with Grid Pattern:
1x 21-1/2in (Tower Bottom Crossbar)
2x 1-1/2in (Tower Riser)
3/4in Dead Axle Tube:
2x 26-7/8in (Tower Brace)
2x1 Light MAXTube:
1x 19-1/2in
1x 23-1/2in
2x1 MAXTube with MAX Pattern:
2x 13in
2x 9in
2x 23in (Stock Length)
2x 31in (Stock Length)
1x1 MAXTube:
2x 13-3/8in (one end must have a hole 1/2in from the edge of the tube)
1x 15in
1/2in Rounded Hex Shaft (Tap Both Ends):
1x 1-1/2in
1x 15in
1x 18-1/2in
1x 20-1/2in
1x 20-3/4in
1x 20-7/8in
1x 23-1/4in
1x 25-5/8in
MAXSpline Shaft:
1x 22in
3/4in Dead Axle Tube:
1x 23-3/8in
#25 Chain:
2x 8in (32 links)
2x 46in (184 links- plus or minus a few links for the turnbuckles)
2x 72in (288 links- plus or minus a few links for the turnbuckles)
Counting from the first hole on the factory edge of the 23in , insert 5 MAXTube Internal Supports so that they align with holes, 13, 17, 23, 24,and 25. Note: Please see our guide to for tips on measuring for your cuts
Note: Please see our guide to for tips on measuring for your cuts
Follow the below links to cut out the hood for the intake then rivet the hood together as shown. Note: If possible, referencing the for this step will give you a good representation of what the hood looks like mounted.
Instructions on how to build the ION West Coast Drive are found here: You can also check out the CAD on OnShape here:
Build TWO of the following structures (described in steps 1-10).
1) Take the 13-3/8in long length of 1x1 MAXTube, and locate the end of the tube with a hole 1/2in from the end. This is the bottom end of the tube.
2) Fasten a plastic 1/2in hex MAXHub to the bottom end of the 1x1 MAXTube using 1-1/2in long #10-32 socket head cap screws and nylock nuts. Tighten the screws very gently to avoid crushing the tube.
3) Match up the hole patterns on a 60T MAXSpline gear and a 2-position MAX Pattern Plate.
4) Insert four 1-5/8in long #10-32 button head cap screws through the gear and plate as shown. Three of the screws should pass through both the gear and the plate, and one screw goes through the plate only.
5) Slide the 1x1 MAXTube onto the two lower screws, with the MAXHub on the opposite side of the assembly from the gear.
6) Install two 1in long #10 plastic spacers on the top two screws.
7) Place a second 2-position MAX Pattern Plate on the opposite side of the 1x1 MAXTube with the screws inserted through the proper holes.
8) Fasten the assembly in place with #10-32 nylock nuts.
9) Install a rounded hex bearing in the gear.
10) Install a rounded hex bearing in the MAX Pattern Plate opposite the gear. Set aside the two completed structures.
11) Slide seven 2in OD 1/2in hex bore compliant wheels onto the 15in long hex shaft.
12) Place the two structures that you set aside in step 10 on either side of the hex shaft and insert the shaft into each of the MAXHubs.
13) Fasten the hex shaft in place with a 1-1/4in long #10-32 button head screw on each end. Take care not to crush the 1x1 MAXTube when tightening the screws.
14) Place the 15in long piece of 1x1 MAXTube between the two upright MAXTube 1x1s. Line the center row of holes up with the 10th hole down on the upright MAXTube 1x1s. This should mean the edge of the 15in MAXTube 1x1 is ~4-3/8in from the top end of the upright MAXTube 1x1s.
15) Place 90 Degree Brackets on either side of the MAXTubes as shown and fasten in place with 3/16in rivets.
1) Install two bearings into the 13in long 2x1 MAXTube with MAX Pattern. Place the bearings on either side of the tube, in the second hole from the end.
2) Install a Structural MAXHub on one side of the tube. This side is now the “outboard” side. Rotate the hub so that the threaded hole is aligned with the centerline of the tube and is located on the left side when viewing the hub from the outboard side of the tube.
3) Install a plastic 1/2in Hex MAXHub opposite the structural MAXHub on the "inboard" (or opposite) side of the tube. Rotate the hub so that the threaded hole is aligned with the centerline of the tube and is located on the left side when viewing the hub from the inboard side of the tube.
4) Fasten the two MAXHubs together with a combination of a 1in long #10-32 socket hex cap screw and a 1in long #10-32 button head cap screw. The socket head screw passes through the plastic MAXHub and threads into the Structural MAXHub. The button head screw passes through the Structural MAXHub and threads into the plastic MAXHub. Take care not to over-tighten the screws and damage the tube or the MAXHubs.
5) Place a MAX Pattern T bracket on either side of the MAXTube. Line the brackets up with the last hole (on the opposite end of the tube from the MAXHubs) with the leg of the brackets facing downward. Fasten the brackets in place with 3/16in rivets.
6) Insert the end of the 9in long 2x1 MAXTube with MAX Pattern between the T brackets.
7) Stack up two MAXSpline Spacers with MAX Pattern and one 64T #25 Plate Sprocket. Align the MAX Patterns in all three parts.
8) Insert four 3in long #10-32 button head cap screws in the four corner holes of the MAX Pattern. Insert the screws through the sprocket first and then through the spacers.
9) Install the spacer and sprocket stack on the joint formed by the MAX Pattern T bracket and 9in long MAXTube. The stack should be installed on the outboard side of the assembly and the four screws should be inserted into the holes in the available MAX Pattern. This joint should be left loose until later in the assembly process. Nuts may be added to the bolts by hand to prevent the screws from falling out during subsequent assembly steps, but the nuts will have to be removed eventually.
10) Insert a Stepped Bushing in the 64T plate sprocket from the outboard side.
11) Install a Stacked MAXSpline bracket onto the bottom of the 9in long MAXTube. The bracket should protrude on the rear side of the assembly as shown. Fasten the bracket in place with 3/16in rivets.
12) Place a Stacked MAXSpline bracket onto the opposite side of the MAXTube from the bracket in the previous step. Insert a plastic 1/2in hex MAXHub into the bracket and into the MAXSpline in the MAXTube. Rotate the MAXHub so that the threaded hole is in line with the centerline of the tube and towards the bottom of the assembly.
13) Fasten the Stacked MAXSpline bracket in place with 3/16in rivets. Ensure that the MAXHub stays inserted during the riveting process to ensure alignment.
14) Insert a Structural MAXHub opposite the plastic MAXHub in the outboard Stacked MAX Pattern bracket. Rotate the MAXHub so that the threaded hole is in line with the centerline of the tube and towards the top of the assembly.
15) Fasten the two MAXHubs together using one 1-1/4in long #10-32 socket head cap screw and one 1-1/2in long #10-32 button head cap screw. The socket head screw should be inserted through the plastic MAXHub and threaded into the Structural MAXHub. The button head screw should be inserted through the Structural MAXHub and threaded into the plastic MAXHub.
16) Place two 1in long #10 spacers in between the Stacked MAX Pattern brackets in the locations shown and slide a 1-1/2in long #10-32 button head cap screw through each of them.
17) Place a nylock nut on the top screw and tighten it down. The bottom screw will need to be left without a nut for a later assembly step, however, it can be temporarily retained with a hand-tight nut which can be removed later.
1) Assemble a MAXPlanetary with a 48:1 ratio. Install the 1-1/2in long hex shaft in the output stage, instead of the shaft that ships with the gearbox. Ensure that the shaft is retained in the output stage using the button head screw included with the gearbox. If you are unsure how to do this, find directions here: MAXPlanetary Assembly Instructions
2) Slide one 1/4in long and one 1/8in long Hex Shaft Spacer onto the MAXPlanetary output shaft.
3) Form one of the 8in long pieces of #25 chain into a loop. This can be accomplished with a chain tool or by removing an extra link and using a connecting link.
4) Loop the chain around two 16T sprockets.
5) Slide the chain and sprockets inside one of the 13in long MAX Pattern MAXTubes. Roughly line the sprockets up with the 2nd and 3rd MAXSplines from the end of the tube.
6) Insert the MAXPlanetary output shaft through the 3rd MAXSpline on the tube and into the rearmost sprocket. Line up the mounting holes on the front of the gearbox with the MAX Pattern holes. The side of the tube that the MAXPlanetary is installed on is the “inboard” side.
7) Mount the MAXPlanetary with two 1/2in long #10-32 button head cap screws installed through the inner wall of the MAXTube. Small pliers may be necessary to insert these screws.
8) Insert a Rounded Hex Bearing on the end of the MAXPlanetary output shaft. The bearing should slide onto the shaft and into the MAXSpline in the MAXTube.
9) Install a Shaft End Screw at the end of the MAXPlanetary output shaft.
10) Slide a Rounded Hex Bearing and a 1/8in long Hex Shaft Spacer onto the 20-7/8in long hex shaft. Take care that the flange of the bearing is oriented as shown.
11) Insert the shaft through the 2nd MAXSpline in the tube and into the sprocket. Slide the shaft through so that some extra length protrudes out of the opposite side of the tube.
12) Slide the bearing into the MAXSpline in the tube.
13) Place a bearing on the end of the protruding hex shaft.
14) Slide the bearing down the shaft and press it into the MAXSpline in the tube. If necessary, use the hex shaft as a lever to tension the chain while sliding the bearing into place.
15) Push the hex shaft until it is flush with the bearing and install a Shaft End Screw at the end of the shaft.
16) Install a Structural MAXHub in the first hole on the MAXTube, on the face opposite from the MAXPlanetary. This side is the “outboard” side. Rotate the hub so that the threaded hole is aligned with the centerline of the tube and located on the right side when viewing the hub from the outboard side of the tube.
17) Install a plastic 1/2in Hex MAXHub opposite of the structural MAXHub on the inboard side of the tube. Rotate the hub so that the threaded hole is aligned with the centerline of the tube and located on the right side when viewing the hub from the inboard side of the tube.
18) Fasten the two MAXHubs together with a combination of a 1in long #10-32 socket hex cap screw and a 1in long #10-32 button head cap screw. The socket head screw passes through the plastic MAXHub and threads into the Structural MAXHub. The button head screw passes through the Structural MAXHub and threads into the plastic MAXHub. Take care not to over-tighten the screws and damage the tube or the MAXHubs.
19) Place a MAX Pattern T bracket on either side of the MAXTube. Line the brackets up with the last hole (on the opposite end of the tube from the MAXHubs) with the leg of the brackets facing downward. Fasten the brackets in place with 3/16in rivets.
20) Insert the end of the 9in long 2x1 MAXTube with MAX Pattern between the T brackets.
21) Stack up two MAXSpline Spacers with MAX Pattern and one 64T #25 Plate Sprocket. Align the MAX Patterns in all three parts.
22) Insert four 3in long #10-32 button head cap screws in the four corner holes of the MAX Pattern. Insert the screws through the sprocket first and then through the spacers.
23) Install the spacer and sprocket stack on the joint formed by the MAX Pattern T bracket and 9in long MAXTube. The stack should be installed on the outboard side of the assembly and the four screws inserted into the holes in the available MAX Pattern. This joint should be left loose until later in the assembly process. Nuts may be added to the bolts by hand to prevent the screws from falling out during subsequent assembly steps, but the nuts will have to be removed eventually.
24) Insert a Stepped Bushing in the 64T plate sprocket from the outboard side.
25) Install a Stacked MAXSpline bracket onto the bottom of the 9in long MAXTube. The bracket should protrude on the rear side of the assembly as shown. Fasten the bracket in place with 3/16in rivets.
26) Place a Stacked MAXSpline bracket onto the opposite side of the MAXTube from the bracket in the previous step. Insert a plastic 1/2in hex MAXHub into the bracket and into the MAXSpline in the MAXTube. Rotate the MAXHub so that the threaded hole is in line with the centerline of the tube and towards the bottom of the assembly.
27) Fasten the Stacked MAXSpline bracket in place with 3/16in rivets. Ensure that the MAXHub stays inserted during the riveting process to ensure alignment.
28) Insert a Structural MAXHub opposite the plastic MAXHub in the outboard Stacked MAX Pattern bracket. Clock the MAXHub so that the threaded hole is in line with the centerline of the tube and towards the top of the assembly.
29) Fasten the two MAXHubs together using one 1-1/4in long #10-32 socket head cap screw and one 1-1/2in long #10-32 button head cap screw. The socket head screw should be inserted through the plastic MAXHub and threaded into the Structural MAXHub. The button head screw should be inserted through the Structural MAXHub and threaded into the plastic MAXHub.
30) Place two 1in long #10 spacers in between the Stacked MAX Pattern brackets in the locations shown and slide a 1-1/2in long #10-32 button head cap screw through each of them.
31) Place a nylock nut on the top screw and tighten it down. The bottom screw will need to be left without a nut for a later assembly step, however, it can be temporarily retained with a hand-tight nut which can be removed later.
1) Insert the 22in long piece of MAXSpline Shaft into the right side structure assembly on the MAXSpline with the sprocket and spacer stackup. The MAXSpline Shaft should be pressed in until it is bottomed out on the stepped bushing in the sprocket. Take care to seat the MAXSpline shaft fully without pushing the bushing out of the sprocket.
2) Install a MAXSpline shaft collar on the MAXSpline Shaft so that the holes in the collar line up with the holes in the MAX Pattern T bracket on the structure. Slide the shaft collar into position so that the four screws from the structure pass through the shaft collar.
3) Fasten the shaft collar in place with four nylock nuts. Alternate between tightening the nuts and tightening the two shaft collar screws.
4) Install a second MAXSpline shaft collar on the MAXSpline Shaft. Leave the collar loose for use later.
5) Install rounded hex bearings in either side of two 3in Omni Wheels.
6) Install one end of the 18-1/2in long Rounded Hex Shaft onto the exposed end of the 1-1/2in long #10-32 Button Head Screw at the bottom of the right side structure assembly. Tighten the screw.
7) Slide the following components onto the 18-1/2in long rounded hex shaft in order: a. 1x 1/2in Long Shaft Spacer b. 1x 3in Omni Wheel (with installed bearings) c. 1x 1/2in Hex Shaft Collar
8) Push the components up against the right side structure assembly and tighten the collar down.
9) Slide the following components onto the 18-1/2in long rounded hex shaft in order (leave these components loose on the shaft): a. 1x 1/2in Hex Shaft Collar b. 1x 3in Omni Wheel (with installed bearings) c. 1x 1/2in Long Shaft Spacer
10) Insert the 20-3/4in long hex shaft into the MAXHub at the bottom of the right side structure assembly.
11) Fasten the end of the hex shaft in place with a 1/2in long #10-32 button head cap screw.
12) Slide seven 2in OD 1/2in hex bore compliant wheels onto the 20-3/4in long hex shaft. Space the wheels so that they match up with the wheels assembled onto the moving gripper jaw earlier.
13) Slide the following components in order onto the jaw powertrain hex shaft: a. 1x 1/16in long Shaft Spacer b. 1x 1/8in long Shaft Spacer c. 1x 20T gear (Note which direction the small notch on the boss of the gear is facing when it is installed. It will be aligned with one of the corners of the hex shaft.) d. 1x 1/2in Shaft Spacer e. 1x 1/2in Hex Shaft Collar
14) Push the components against the bearing and tighten the shaft collar.
15) Slide the following components in order onto the jaw powertrain hex shaft (leave these components loose on the shaft): a. 1x 1/2in Hex Shaft Collar b. 1x 1/2in Shaft Spacer c. 1x 20T gear (The alignment notch on this gear must be facing the same direction as the other 20T gear.) d. 1x 1/8in long Shaft Spacer e. 1x 1/16in long Shaft Spacer
16) Insert the 20-3/4in long hex shaft into the MAXHub at the top of the right side structure assembly.
17) Fasten the end of the hex shaft in place with a 1/2in long #10-32 button head cap screw.
1) Slide one 1/16in long Shaft Spacer onto the frontmost shaft of the gripper assembly (the jaw pivot shaft).
2) Slide the moving gripper jaw onto the hex shaft and up against the spacer. Ensure that the gear on the jaw meshes with the gear on the jaw powertrain shaft.
3) Slide one 1/16in long Shaft Spacer onto the jaw pivot hex shaft.
4) Mate the left side structure assembly with the gripper assembly. The structure will connect with the existing assembly at five points:
Jaw pivot shaft - Bottom out on the structural MAXHub on the front of the left side structure assembly.
Jaw powertrain shaft - Pass the shaft through the two bearings on the left side structure assembly.
MAXSpline shaft - Pressed into the proper MAXSpline on the left side structure assembly until it is bottomed out on the stepped bushing in the sprocket.
Lower compliant wheel shaft - Bottom out on the structural MAXHub at the bottom of the left side structure assembly.
Omni wheel shaft - Mate with the loose screw on the bottom of the left side structure assembly. Tighten this screw down.
5) Retain the jaw pivot shaft and the lower compliant wheel shaft with 1/2in long #10-32 button head cap screws.
6) Retain the jaw powertrain shaft with a Shaft End Screw.
7) Slide the loose MAXSpline shaft collar on the MAXSpline Shaft into position so that the four screws from the structure pass through the shaft collar.
8) Fasten the shaft collar in place with four nylock nuts. Alternate between tightening the nuts and tightening the two shaft collar screws.
9) Push the loose components on the omni wheel shaft up against the left side structure assembly and tighten the shaft collar.
10) Slide the loose components on the jaw powertrain shaft up against the bearing in the left side structure assembly. Ensure that the gear meshes with the gear on the moving gripper jaw. If the gears do not mesh, go back and check that the alignment notches on both gears are facing the same direction.
11) Tighten the shaft collar to hold the components in place on the jaw powertrain shaft.
1) Install two tube nuts in either end of the 23-3/8in long 3/4 Dead Axle Tube.
2) Set this assembly aside.
1) Arrange two 31in long MAXTubes with MAX Pattern and one 23-1/2in long 2x1 Light MAXTube on a flat surface as shown. The 23-1/2in long tube forms a crossmember that should be offset from the ends of the 31in long tubes by 8in.
2) Line up four 90 Degree brackets as shown (top and bottom) and rivet them in place.
3) Build two of the following structures from steps 3-5. Align the MAXSpline and holes of a 64T #25 chain plate sprocket and a MAXSpline Spacer with Holes.
4) Insert a Rounded Hex Bearing into the MAXSplines from the sprocket side.
5) Insert four 1-5/8in #10-32 button head screws through the four holes as shown.
6) Insert the two sprocket and spacer assemblies from steps 3-5 the inside into the first MAX Pattern instance on the 31in long MAXTubes.
7) Add nuts to the screws and gently tighten them down. Take care not to overtighten the screws and crush the tube.
8) Insert a Rounded Hex Bearing in the outside of each 31in MAXTube aligned with the sprockets.
9) Install Structural MAXHubs on either side of each of the 31in MAXTubes on the end opposite the sprockets.
1) Insert the 3/4in Dead Axle Tube assembly through the bushings in the gripper assembly. Line it up so it protrudes an equal amount on either side.
2) Install external retaining rings on either side of the tube. Ensure that the retaining rings fit tightly. If a tighter fit is required, the teeth of the retaining ring can be tweaked with a pair of pliers to grip tighter.
3) Insert the gripper assembly between the tubes of the arm assembly and line the Dead Axle Tube up with the Structural MAXHubs on the arm as shown. Ensure that the gripper is oriented as shown (facing “inwards” towards the arm).
4) Fasten the Dead Axle Tube in place with a 1-5/8in long #10-32 button head screw on either side.
1) Build two of the following: a. Insert a MAXTube Endcap into each end of the “Tower Riser” tubes (refer to the Cutting and Tapping section for the lengths depending on the type of drivetrain being used). b. Secure the endcaps in place with eight (8) 3/8in long #10-32 button head screws (four in each endcap).
2) Space the “Tower Risers” evenly underneath the “Tower Bottom Crossbar” so that the inside faces of the risers are the correct distance apart and they are the same distance from the ends of the bottom crossbar. See the following list for how far apart the risers should be spaced (inside to inside) depending on the drivetrain type:
ION WCD: 20-1/2in
KOP Drivetrain: 18-1/2in
3) Screw the tower risers in place with six 3/8in long #10-32 button head screws (three per riser) from inside the bottom crossbar.
4) Set up two 23in long 2x1 MAXTubes with MAX Pattern vertically on the ends of the “Tower Bottom Crossbar” so that the tubes are 19-1/2in apart (inside to inside) and spaced evenly from either side of the bottom crossbar.
5) Line up 90 Degree brackets on both sides of the tubes on the corners of the structure and rivet them in place as shown.
6) Position the 19-1/2in long 2x1 Light MAXTube between the upright tubes so that it forms a crossbar with its top surface 6in from the top ends of the upright tubes.
7) Line up 90 Degree brackets on both sides of the tube and rivet them in place as shown.
8) Build two of the following: a. Align the MAXSpline and holes of a 64T #25 chain plate sprocket and a MAXSpline Spacer with Holes. b. Insert an Aluminum MAXHub into the MAXSplines from the sprocket side. c. Insert four 1-5/8in #10-32 button head screws through the four holes as shown.
9) Insert the sprocket and spacer assemblies from the outside into the top MAX Pattern instance on the 23in long MAXTubes.
10) Add nuts to the screws and gently tighten them down. Take care not to overtighten the screws and crush the tube.
11) Insert an Aluminum MAXHub in the inside of each 23in MAXTube aligned with the sprockets. Rotate the MAXHubs so that their tapped holes are turned 180 degrees from the tapped holes on the hubs on the other side of the tube.
12) Retain the MAXHubs with 1-1/4in long #10-32 socket head screws inserted from either side.
13) Assemble a MAXPlanetary with a 48:1 ratio. Install the 3in long hex shaft (that ships with the gearbox) in the output stage. Ensure that the shaft is retained in the output stage using the button head screw included with the gearbox. If you are unsure how to do this, find directions here: MAXPlanetary Assembly Instructions
14) Insert the MAXPlanetary in the bottom MAXSpline on the upright tube that will become the left side of the robot.
15) Install a Rounded Hex Bearing to support and align the shaft.
16) Fasten the MAXPlanetary in place with two 1-1/4in long #10-32 button head screws. Take care when tightening the screws to avoid crushing the tube.
17) Slide a 1/16in wide Shaft Spacer onto the gearbox shaft.
18) Insert two Rounded Hex Bearings on the insides of the upright tubes (one bearing in each tube) and one Rounded Hex Bearing in the outside of the right side tube.
19) Insert the 23-1/4in long hex shaft through the bearing on the left side upright tube. Do not slide the shaft all the way through to the right side bearing.
20) Slide two shaft collars onto the hex shaft (between the two upright tubes). Leave the shaft collars loose on the shaft.
21) Slide (in order) one Rounded Hex Bearing and one 1/16in Shaft Spacer onto the 23-1/4in hex shaft on the left side end of the shaft. Do not insert the bearing into the MAXSpline in the tube yet.
22) Form one of the 8in long pieces of #25 chain into a loop. This can be accomplished with a chain tool or by removing an extra link and using a connecting link.
23) Loop the chain around one 16T #25 single chain sprocket and one 16T #25 double chain sprocket.
24) Slide the chain and sprockets onto the ends of the two hex shafts on the left side. The single sprocket goes on the gearbox shaft and the double sprocket goes on the 23-1/4in long shaft. The unused side of the double sprocket should be placed on the outside. Make note of what orientation the alignment notch is on the double sprocket (it will be aligned with one of the corners of the hex shaft).
25) Slide both sprockets along with the bearing and spacers towards the tube. Insert the bearing into the MAXSpline and ensure all the components are fully seated against the faces of the bearing. It may be necessary to apply tension to the chain by pushing on the opposite end of the 23-1/4in hex shaft.
26) Install a shaft collar on the gearbox shaft.
27) Slide the 23-1/4in hex shaft through the bearings in the right side upright tube. Take care not to allow the bearing on the inside of the left upright to pop out while sliding the shaft. Slide the shaft until its end is flush with the face of the double sprocket.
28) Install one 1/16in wide, one 1/8in wide, and one 1/4in wide Shaft Spacer onto the right side end of the 23-1/4 hex shaft.
29) Install a 16T #25 chain sprocket on the end of the shaft up against the spacers. Ensure that the alignment notch on this sprocket is oriented the same direction as the alignment notch on the double sprocket on the other end of the shaft.
30) Retain the 23-1/4in hex shaft with a Shaft End Screw on either end.
31) Push the shaft collars up against the inside bearings on each upright and tighten them down.
32) Press one right hand Tube Nut into one end of the “Tower Brace” Dead Axle Tube. Push the tube nut in so the barbs are slightly below flush, but do not push it in further than necessary.
33) Press one left hand Tube Nut into the opposite end of the tower brace. Push the tube nut in so the barbs are slightly below flush but do not push it in further than necessary. Make a mark on the tube (e.g. with a permanent marker or a piece of tape) which end is the left hand end.
34) Install (in order) one right hand Jam Nut and one Oversize #10 Washer onto a right hand Ball Joint Rod End.
35) Thread the rod end into the right hand tube nut on the tower brace tube. Leave the rod end and nut loose.
36) Install (in order) one left hand Jam Nut and one Oversize #10 Washer onto a left hand Ball Joint Rod End.
37) Thread the rod end into the left hand tube nut on the tower brace tube. Leave the rod end and nut loose. Repeat steps 32-37 until you have two of these structures, then set them aside.
38) Insert two 1-5/8in long #10-32 button head screws (one in each side) into holes in the upright tubes shown below.
39) Slide two 1/8in long #10 spacers onto the ends of the screws in the uprights (one in each side).
40) Install the right hand ends of the tower brace assemblies onto the ends of the screws in the uprights.
41) Install nylock nuts onto the screws to fasten the tower braces in place. Take care not to overtighten the screws and crush the tubes.
1) Place a 2x1 MAXTube Endcap on either drive rail of the drivetrain towards the rear. The center of the rearmost hole on the endcap should be 5-1/2in from the rear surface of the drivetrain frame.
2) Fasten the endcap in place with four 2-1/2in long #10-32 button head screws (two per endcap) from the bottom of the drive rail.
3) Set the tower assembly onto the drivetrain so that the front of the tower tubes are 3-1/2in from the front surface of the drivetrain frame.
4) Fasten the tower risers in place with four 2-1/2in long #10-32 button head screws (two per riser) from the bottom of the drive rail.
5) Use two 1/2in long #10-32 button head screws (one per side) to fasten the ends of the tower braces to the rearmost hole on the inside surface of the endcaps attached to the frame. It may be necessary to adjust the length of the tower braces (by rotating the 3/4in tube while holding the free rod end still) in order to get the rod ends to line up with the holes in the endcaps.
6) Tighten the tower braces by rotating the 3/4in tubes so that braces are pulling on the tower (not pushing). Only a small amount of force is required in order to provide adequate support to the tower.
7) Lock the tower braces in place by tightening the jam nuts on either side of the braces while holding the 3/4in tubes still.
1) Set the tower assembly onto the drivetrain so that the front of the tower tubes are approximately 3-3/16in from the front surface of the drivetrain frame (this is an approximate number- the most important thing is that the holes line up between the drivetrain and tower riser endcaps).
2) Fasten the tower risers in place with four 1/2in long #10-32 button head screws (two per riser) from the underside of the top flange of the inner drive rails. It may be necessary to remove the front wheel to perform this installation.
3) Use two 3/4in long #10-32 button head screws (one per side) and nylock nuts to fasten the ends of the tower braces to the top 0.201in hole on the inside face of the inner drive rails (see image). It may be necessary to adjust the length of the tower braces (by rotating the 3/4in tube while holding the free rod end still) in order to get the rod ends to line up with the holes in the drivetrain.
4) Tighten the tower braces by rotating the 3/4in tubes so that braces are pulling on the tower (not pushing). Only a small amount of force is required in order to provide adequate support to the tower.
5) Lock the tower braces in place by tightening the jam nuts on either side of the braces while holding the 3/4in tubes still.
1) Slide the 25-5/8in long hex shaft through one side of the bearings in the arm assembly. Only about 1/16in should be protruding on the inside of the inner bearing.
2) Slide a spare piece of hex shaft through the bearings on the other side of the arm assembly with a similar 1/16in protruding on the inside of the inner bearing.
3) Slide 1/16in wide Shaft Spacers onto the exposed shafts.
4) Line the shafts up with the MAXHubs at the top of the tower.
5) Push the 25-5/8in shaft through the MAXHubs across the tower structure and through the MAXHubs on the other side. Allow the shaft to push the spare hex shaft out of the way so that the spacer ends up on the 25-5/8in shaft. Finally, pass the shaft through the bearings on the other side so that the shaft is flush with the outer bearing.
6) Retain the shaft with two Shaft End Screws.
7) Extend four Chain Turnbuckles to their fully extended size.
8) Loop the two 184-link chains around the outer 64T sprockets at the top of the robot and the exposed 16T double sprockets at the bottom. Position the chain so the two ends meet as close to the bottom sprocket as possible on the rear side of the tower.
9) Fasten two of the Chain Turnbuckles to one end of each chain (one turnbuckle per chain) with connecting links.
10) Make note of where the chain lines up on the turnbuckle and remove any extra links as necessary to bring the chain into the range where the turnbuckle can tension it. Note that the turnbuckle can only be adjusted inwards at this point, so the chain will likely be too long even after removing links. Also note that the connecting links require a narrow link at the end of the chain.
11) Fasten the remaining ends of the Chain Turnbuckles to the remaining ends of the chains with connecting links.
12) Adjust the turnbuckles to tension the chain. The mechanism will benefit from a very tight chain, but take care to avoid over-tightening and damaging other motion components (bearings, shafts, gearboxes, etc.). If the chain turnbuckles reach their fully retracted positions and the chain isn’t tight, repeat the last few steps to remove links from the chain and reattempt tensioning.
13) Position the gripper so that the top tube is inclined by about 30-40 degrees from level.
14) Loop the two 288-link chains around the inner 64T sprockets at the top of the robot and the 64T sprockets on the gripper. Position the chain so the two ends meet as close to the gripper sprocket as possible on the top side of the arm.
15) Fasten two of the Chain Turnbuckles to one end of each chain (one turnbuckle per chain) with connecting links.
16) Make note of where the chain lines up on the turnbuckle and remove any extra links as necessary to bring the chain into the range where the turnbuckle can tension it. Note that the turnbuckle can only be adjusted inwards at this point, so the chain will likely be too long even after removing links. Also note that the connecting links require a narrow link at the end of the chain.
17) Fasten the remaining ends of the Chain Turnbuckles to the remaining ends of the chains with connecting links.
18) Adjust the turnbuckles to tension the chain. The mechanism will benefit from a very tight chain but take care to avoid over-tightening and damaging other motion components (bearings, shafts, gearboxes, etc.). If the chain turnbuckles reach their fully retracted positions and the chain isn’t tight, repeat the last few steps to remove links from the chain and reattempt tensioning.
