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kit:assembly_outline

This is the outline of the assembly instructions for the new CrowBox (internal note: Ploppy v007)

Set up your work area

  • Find an open, flat work surface with plenty of light. Kitchen table? Perfect.
  • If you like your table, find something to put down to protect it while you work.
    • Newspaper is OK, but use several layers.
    • A flap or side panel from a large cardboard box is perfect.

Using hot glue

FIXME - Currently just data in outline form. Write this out

  • Use a “high temperature” glue gun, not a cheapo craft store gun
  • Recommend “BestStik” high-temperature glue sticks from Surebonder
  • Use alcohol to release hot glue, DO NOT use a knife
  • Keep a cup of cool water nearby in case hot glue gets on skin

Using plastic cement

FIXME - Data in outline format, write it out

  • Explain cement vs. glue
  • Recommend Sci-Grip 16 (medium-bodied) brand solvent cement
  • Recommend precision applicator tip

Build Phase One: Sub-assemblies

In this first phase we'll be taking various acrylic parts from the CrowBox kit and assembling them into larger parts of the machine. In Phase Two we'll put the finished machine together from these sub-assemblies.

Baseplate sub-assembly

The Baseplate is the platform upon which the entire CrowBox is built. In this step we'll be adding some reinforcement to the baseplate to make it stronger at the points where the CrowBox will be screwed to a pole or platform.

Gather Parts & Supplies

  • Machine Baseplate x1
  • Reinforcing ring x4
  • Plastic cement

Build it!

  1. Peel the protective paper from one side of the baseplate
  2. Set the baseplate, peeled side UP, on your work surface
  3. Peel the protective paper from both sides of each reinforcing ring
  4. For the next steps, attach one ring at a time then move on to another
    1. Apply a thin bead of plastic cement around one of the holes in the baseplate
    2. Place one reinforcing ring over the same hole and carefully adjust its position so that the hole in the reinforcing ring aligns with the hole in the baseplate. The ring should slide easily on the fresh cement
    3. Repeat until all reinforcing rings are in place
  5. Finally, double check that all of the rings are still properly aligned, then set this sub-assembly aside to dry.

Basket Faceplate sub-assembly

Gather Parts & Supplies

  • Transparent basket faceplate
  • Transparent ribs (2 pieces)
  • Plastic cement
  • M3x10mm machine screws (4)
  • M3 nuts (4)

Build It!

  1. Peel protective paper from both side of the basket faceplate
  2. Peel protective paper from both sides of both transparent ribs
  3. Push one machine screw through each of the four holes in the basket faceplate
  4. Place the faceplate flat on your work surface with the screw shanks pointing up
  5. Thread one rib onto the screws by aligning the two holes in the rib with a pair of corresponding screws sticking out of the faceplate - Do not push the rib all the way down against the faceplate yet!
  6. Apply a thin line of cement to the faceplate, directly below the rib
  7. Gently work the rib down the screw shanks until it is flat against the faceplate and pressed into the cement
  8. Repeat the previous step with the other rib
  9. Thread an M3 nut onto each machine screw and hand-tighten
  10. Set this sub-assembly aside to dry

Machine Faceplate sub-assembly

The front of the machine

Gather Parts & Supplies

  • Machine faceplate
  • Small ribs (solid color) (2)
  • Large ribs (2)
  • Plastic cement
  • M3x10mm machine screw (6)
  • M3 nuts (6)

Build It!

Note: Small ribs must be installed first!

  1. FIXME - Steps!

Coin Slide sub-assembly

The Coin Slide is an acrylic ramp that catches coins from the funnel and transmits them to the inside of the CrowBox for storage. The coin slide features a network of thin copper wires which also electronically detect the metal coin as it slides into the CrowBox for storage.

Gather Parts & Supplies

  • Coin slide x1
  • Coin slide side rails x2
  • 24 gauge bare copper wires. 7×12 inch lengths
  • 3M self-adhesive noise dampening mat
  • Plastic cement

Build it!

  1. Peel all protective paper from all acrylic parts
  2. Cement side rails to coin slide
  3. Attach and trim sound dampening material
  4. Weave the wires

Rail sub-assemblies

Here we'll assemble the rails upon which the basket lid will slide. These rails also contribute to the overall structural strength of the CrowBox machine.

Gather Parts & Supplies

  • Rail (2)
  • Rail lower ledge (2)
  • M3x10mm machine screw (4)
  • M3 nut (4)
  • Plastic cement

Build It!

  1. FIXME : Bleah, confusing
  2. Orientation of parts is particularly important in this assembly
  3. Peel protective paper from both sides of all four acrylic parts
  4. Lay the two rails flat on your work surface, arranged as shown
    1. FIXME - [Image: Show rail orientation]
  5. Go through the following steps one entire rail at a time, then repeat for the other rail
    1. Push two machine screws through the bottom pair of holes in the rail
    2. Apply a thin line of cement between and beyond the screws on each rail
      1. FIXME - [Image: demonstrate glue bead line]
    3. Align the two holes in a lower ledge over the upturned screws in the rail and press the lower ledge down into the line of cement
    4. Thread an M3 nut onto each screw and hand-tighten

Rotor sub-assembly

In this step we'll assemble the rotor, which transmits power from the servo motor to the sliding lid, allowing the reward basket to be opened and closed.

Gather Parts & Supplies

  • Rotor
  • Rotor servo shoe
  • Plastic cement
  • M3x10mm machine screw (3)
  • M3 nut (3)

Build It!

  1. Peel protective paper from both sides of the rotor
  2. Peel protective paper from both sides of the rotor servo shoe
  3. Push one M3 machine screw through each of the holes in the rotor
  4. Place the rotor flat on your work surface with screw shanks facing up
  5. Apply three small dots of cement to the rotor, placing one dot between each pair of holes in the rotor
    1. [IMAGE]
  6. Thread the rotor servo shoe onto the three upturned machine screws in the rotor and carefully work the shoe down until it presses flush against the rotor
  7. Thread an M3 nut onto each screw and hand-tighten
  8. Set this sub-assembly aside to dry

Coin Magazine sub-assembly

The coin magazine holds the CrowBox's supply of training coins, which will later be automatically dispensed to help train Crows.

Gather Parts & Supplies

  • Coin magazine side panels (2)
  • Coin magazine front panel
  • Coin magazine rear panel
  • Coin magazine skids (2)
  • Silicone band
  • Plastic Cement

Build It!

  1. FIXME - These instructions aren't great
  2. Peel the protective paper from both sides of all six coin magazine parts
  3. NOTE: The four sides of the coin magazine can only be assembled one way so don't worry about getting it wrong
  4. Arrange together all four side panels of the coin magazine to form a square tube
    1. FIXME - [IMAGE]
  5. Hold this square tube together gently with one hand, and with the other work the silicone band over the tube to hold it together while we cement.
  6. With the band secured (you may need to double loop it), apply a bead of cement along the four inside corner edges of the square tube as shown
    1. FIXME - [IMAGE]
  7. Place the two skids on your work surface, side by side but slightly apart
  8. Apply a thin bead of cement along the long outside edge of each skid
    1. FIXME - [IMAGE]
  9. IMPORTANT: For this next step, make sure you don't have the coin magazine upside down!
  10. Lower the coin magazine onto the skids, adjusting them as necessary to attach as shown
    1. FIXME - [IMAGE]
  11. Double check the 'squareness' of the coin magazine and the position of the skids before setting this sub-assembly aside to dry.
kit/assembly_outline.txt · Last modified: 2018/08/01 13:37 by 127.0.0.1