Wall-E Robot

Last two nights I have been working on the motor drive sprockets.

I had to make an adapter for the centre of the sprocket so I could centre the hole saw in the sprocket for drilling the hole for the hub.
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I then drilled a hole in a board to put the adapter into.
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Now I can put the sprockets on and have a centre hole for the drilling.
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28mm tungsten carbide tipped 28mm Hole Saw.
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Drilled the mounting holes to hold the sprocket onto the hub.
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Drilled the centre hole for the hub.
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Fit perfect.
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Both drive sprockets fitted.
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I also made the plates for holding the clear acrylic for when I make the lenses for the eyes. I will have photos of this tomorrow.
 
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Photos of the plates for making the clear lenses for the eyes.
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The step is to set the reducer into when I'm vacuum forming the lens.
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T nuts installed on back plate. Need to get some bolts for them.
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I got the clear acrylic for the lenses. Just need to cut the sheet down to squares to fit into the 2 plates.

I will be doing the lens like in this video at 3.44
 
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I have drawn up the inner eye details for Wall-E tonight. Drawn up in vector so they can be scaled to any size without loosing quality. I will be printing them on a high tack signage vinyl that will also be cut to size on the printer to fit onto the plastic part in the eye.

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Clear plastic cut to size ready to make eye lens.
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Got the bolts for the lens plates
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Test version of the eye detail stickers.
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Looks good. :) Fits perfect.
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Today I spent a little bit of time working out the lower roller wheels. Bolts are only temporary.

Plates for the lower roller wheels.
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Working out the width of the plates and wheels.
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Bolts will be replaced with axles.
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Got into the shed today and made some axles for the lower roller wheels.
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Worked out the final size of the wheels today. Now to have them made out of rubber and bushing.
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Axles made.
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Got a new tool today. :) Tube notcher.
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My work area.
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This week I got the shafts cut down on the two NPC-2212 motors.

Working on the motor mount.
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Need to shorten the shafts on the motors.

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I made this spacer so I can side it on the shafts to make sure they are all the same length after cutting them.
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Shafts cut down to the right length.
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Next I will be mounting the motor into the motor mount.
 
Motor fits now.
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Working out the size to make the wheel covers that has the details on it and the BNL logo.
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Front sprocket.jpg


Idle Sprocket.jpg


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Test of the new tube notcher. Have made new parts that hold the front axle bearing housing to the motor mount. Will have photos in a day or 2.