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:
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.