REPLACEMENT PARTS
[11/02/2004]
Today, I voted. Last night, I worked on creating some new pieces for Slap Happy. The
battery tray is still not mounted, but I am determined to get it mounted up today.
However, the battery tray and cross plate have both been replaced by the new pieces I
made last night. You can see the new box in this image.
The cross plate was intended to add some strength to the frame by boxing it up a bit,
but some logistical issues arose out of the design of the tray and the cross plate,
and I decided to re-design the whole assembly. The heavy tray is replaced by two
new pieces to which the batteries will be attached with zip ties. The two new pieces
are made out of a thinner gage aluminum, and I haven't weighed them, but I think I
just about broke even on the weight. Here you can see the forward plate to which the
motor controllers will mount. The two holes on the bottom is where the wires to the
motors go through, and the three holes along the top are for the zip ties to secure
the batteries in place. It took a little over an hour to make this part (from layout
to completion).
This is the rear plate that will mount to the rear frame pieces, adding a great deal
more strength to the structure. It's design is very similar (almost identical) to
the forward piece, except I have not cut any holes for wires to the weapon that will
eventually be there. I probably should have cut a hole before I bent the part (and I
thought about that), but I didn't, so I'll deal with it when the time comes. It took
about an hour to make this piece.
Here again the pieces are shown in the orientation where they will be mounted. One
mistake I made on the rear piece is that I bent the battery retaining flanges in
the wrong place (they were supposed to be 1/16" closer in), but that's what happens
when I work too fast. While I was milling the holes, I noticed I didn't mark the
bend line in the right place, but when it came time to bend it, I forgot. D'OH!
Hopefully, this won't be a problem. But I have become so good at working with
aluminum that I can (and might) make another one if it looks like it might be a problem.
I am just concerned with the uneven mating edges chafing against the end of the battery
pack. Perhaps I'll just put some foam tape across it.
Here is a shot with the batteries sitting on top. You can also see a thin metal piece
spanning the rear frame formers. This is just a little retainer clip I made to hold
the pieces at the proper spacing while I mark and drill the holes to mount the new
pieces on. The angles aren't 100% square (nothing is perfect), so the pieces need to
be pulled together slightly at the top so they are square with the base. Today I
plan to drill the mounting holes and bolt the thing together!