M A K E R B O T
Botmobile Dune Buggy 2013
Assembly Manual
Table of Contents
Tools & Part List ....................................................................... 1
Tools & Consumables .............................................................. 1
RC Components ....................................................................... 2
Printing the parts ...................................................................... 5
Print Settings ............................................................................ 5
Assembly ................................................................................. 8
Steering assembly .................................................................... 8
Gearbox & Rear Axle ............................................................. 11
Building the chassis of the Buggy ........................................... 16
Final assembly and RC installation ........................................ 22
Experimental Stuff .................................................................. 26
by Eric Weber
Thingiverse URL: http://www.thingiverse.com/thing:114784
Revision 4
13/7/2013
B O T M O B I L E
Chapter
1
F
Tools & Part List
ollowing tools and components are required to fully assemble the Makerbot
Botmobile 2013. I have indicated the components which I have personally
tested with this design. Although I can’t guarantee it the other variants listed
should work based on their specifications. Please leave a comment on the
Thingiverse model page if you successfully tested other variants so I can add them to
the list below for the benefit of all.
Tools & Consumables
Following tools & consumables are required to finish the Botmobile
•
Sharp hobby knife
•
3mm Drill
•
2.5mm Drill
•
CA Glue
•
Metric hex key/Allen keys of 2 and 2.5mm
•
Double sided Tape
•
Zip ties
•
ABS/PLA suitable grease (e.g. Super Lube)
•
1-2x JST Female 2 pin connector
(source:http://www.hobbyking.com/hobbyking/store/__9631__JST_Fe
male_2_pin_connector_set_10pcs_set_.html )
•
Screws:
•
1x M3x10 Cap Hexagon Socket Screw
•
4x M3x25 Cap Hexagon Socket Screw
•
1x M3x30 Cap Hexagon Socket Screw
•
2x M3x4 Button Hexagon Socket Screw (brushless version only)
•
1x M3x7 Button Hexagon Socket Screw
•
1x M3x15 Button Hexagon Socket Screw
1
B O T M O B I L E
2
RC Components
Following is a list of suggested (and mostly tested) components which will work with
the Makerbot Botmobile 2013. Tested components are indicted with a tick.
RC Transmitter & Receiver
(cheap option in case you do not yet have a surface RC system)
•
HobbyKing HK-GT2B 3CH 2.4GHz Transmitter and Receiver
w/Rechargeable Li-ion Battery
(source:http://www.hobbyking.com/hobbyking/store/__31671__HobbyKin
g_HK_GT2B_3CH_2_4GHz_Transmitter_and_Receiver_w_Rechargable_Li
_ion_Battery.html )
RC Receiver
(For those who already own a Transmitter)
SR201 2Ch DSM Sport Surface Rx - Coated by Spektrum
(source:http://www.horizonhobby.com/products/sr201-2ch-dsm-sport-
surface-rx-coated-SPMSR201 or http://radiocontrol-sports.com/radio-
systems/i-receiver-surface/sr201-2-ch-dsm-sport-surface-rx-coated.html )
9gram Servo
HXT900 9g / 1.6kg / .12sec Micro Servo
(source:http://www.hobbyking.com/hobbyking/store/__662__HXT900_9g
_1_6kg_12sec_Micro_Servo.html )
Option 1: Brushmotor
(Ensure that you print the parts optimized for the brushmotor configuration BuggyInterior Brush.stl & GearboxBrushmotor_supports.stl)
Motor: GWS 280 Motor Set (GW/EDP-150)
(source: Ebay and various other online shops – search for the item code
GW/EDP-150, example: http://shop.rotor.com.sg/show-
detail.asp?prodid={A78F0DCF-B85C-457E-86C06CA1B81FA90D}&pn=1#.UdrWaPml4Z8 )
ESC: HobbyKing X-Car 45A Brushed Car ESC
(source:http://www.hobbyking.com/hobbyking/store/__32025__HobbyKin
g_X_Car_45A_Brushed_Car_ESC.html )
B O T M O B I L E
3
Option 2: Brushlessmotor
(Ensure that you print the parts optimized for the brushlessmotor configuration BuggyInterior Brushless.stl & GearboxBrushlessmotor_supports.stl)
Motor: S2445-3200 Brushless Inrunner (3200kv) (14T)
(source:http://www.hobbyking.com/hobbyking/store/__15185__S2445_320
0_Brushless_Inrunner_3200kv_14T_.html )
ESC: Turnigy TrackStar 18A 1/18th Scale Brushless Car ESC
(source:http://www.hobbyking.com/hobbyking/store/__14630__Turnigy_T
rackStar_18A_1_18th_Scale_Brushless_Car_ESC.html )
Pinion Gear: Pinion Gear 3mm/0.5M 10T (1pc)
(source:http://www.hobbyking.com/hobbyking/store/__11204__Pinion_Ge
ar_3mm_0_5M_10T_1pc_.html )
LiPo Battery
(A LiPo Battery Charger and Balancer is required to charge this type of battery. Do
NOT attempt to charge it with a normal charger as the battery will explode).
Packs with the following dimension will fit the car: 70 x 35 x 13mm
Turnigy 1000mAh 2S 20C Lipo Pack
(source:http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idPr
oduct=9170 )
•
Great Planes LiPo 2S 7.4V 1000mAh Novus 200 FP
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXBPAW&P=7 )
Ball Bearings
(2x standard Skateboard 608 type - 8x22x7 - ball bearings are required)
2x Ball Bearing (22x7x8mm) - 1/5 4WD Big Monster
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXFX65&P=7 )
•
2x 608RS 8x22x7 Bearing
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXFX65&P=7 )
B O T M O B I L E
4
Tires
(The Botmobile requires 4 rubber tires for the printed wheels)
2x Thunder Tiger Fire Blade Tire, 26mm (PD9158)
(source: http://www3.towerhobbies.com/cgi-
bin/WTI0001P?I=LXATAV&P=8 or http://www.amazon.com/Thunder-
Tiger-PD9158-Blade-Tires/dp/B003DKQRZQ/ref=cm_cr_pr_product_top
)
•
2x 1:10 Scale Rubber Touring Car Tires w/Tread 26mm - Medium
Compound (2pcs)
(source:http://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idPr
oduct=23292 )
OPTIONAL
(Connectors you might require for your charging leads/ESC/Motor)
JST Female 2 pin connect
(source:http://www.hobbyking.com/hobbyking/store/__9631__JST_Female
_2_pin_connector_set_10pcs_set_.html )
JST Male 2 pin connector
(source:http://www.hobbyking.com/hobbyking/store/__9630__JST_Male_2
_pin_connector_set_10pcs_set_.html )
B O T M O B I L E
5
Chapter
2
W
Printing the parts
hen I printed the 2 prototypes after modifying the Makerbot original plans
I used exclusively ABS material only. Although the Botmobile should print
fine in PLA, I can’t guarantee that the gears will last given the friction and
resulting heat generated.
The Botmobile 2013 comes in 2 versions. The brush motor version for normal 280
size brush motors such as the suggested GWS motor and the brushless motor variant
which will work with 280 size BL motors and controllers such as the HobbyKing types
in the source list. Please print the correct Buggy interior (to fit the controller switch)
and gear box motor mount (BL and brush motor have different mounting hole
positions and sizes) depending on the variant you select.
Thingiverse download Link: http://www.thingiverse.com/thing:114784
Print Settings
The grouping into color 1 and 2 below is a suggestion. Mix and match as you like.
I printed all parts with 0.2mm layer height for the prototype.
Color Set 1
(Drive train, steering and seats)
•
Axle&Bearing_Clips.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
•
AxleGear.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s
B O T M O B I L E
6
•
GearboxShell.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
•
Gears.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s
•
Steering.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
•
Wheels.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
o Print 2x
Option 1:
•
BuggyInterior Brush.stl (Brushmotor Option)
Print with:
o 10% infill
o 3 shells
o 80mm/s
•
GearboxBrushmotor_supports.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
o Enable supports
B O T M O B I L E
7
Option 2:
•
BuggyInterior Brushless.stl (Brushlessmotor Option)
Print with:
o 10% infill
o 3 shells
o 80mm/s
•
GearboxBrushlessmotor_supports.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
o Enable supports
Color Set 2
(Body, Windshield and RX brackets)
•
BuggyBack.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
•
BuggyFront.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
•
Add_RX_Brackets.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
•
WindShield.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s
B O T M O B I L E
8
Chapter
3
O
Assembly
nce all parts are printed and all components are available, we can put the
Botmobile 2013 Dune Buggy together and take it for a spin.
Follow the picture guide below and also consult the original Makerbot
Botmobile assembly instructions at:
http://www.makerbot.com/support/projects/botmobile/ for additional information
if required.
Steering assembly
Following parts are required to complete the steering assembly:
- All parts from the steering.stl file printed as per description in chapter 2
- 9gram servo with straight servo arm and smallest screw
B O T M O B I L E
9
Attach the swing arms to the control arm
Attach the swing arms and control arm assembled in the previous step to the steering
base.
Attach the steering top mount/servo holder to the assembly as shown above.
B O T M O B I L E
Press the servo into the steering assembly from the bottom (picture above shows the
top view) by first sliding the servo mounting tabs on the cable side into the servo
holder and then snapping in the opposite tabs into the mount. A bit of force might be
required. Use a hex key to push the tab down but be careful not to break them.
Center the servo using the RC Radio. Install the steering arm by pressing the servo arm
into the steering linkage (a bit of trimming might be required for a snug fit) and
afterwards install the steering arm on the servo as shown above. Once secured with the
servo screw, trim the excess servo arm with a hobby knife.
Install the retainer clip as shown above
10
B O T M O B I L E
Gearbox & Rear Axle
Following parts are required to complete the steering assembly:
- All parts from the following stl files printed as per description in chapter 2
o Axle&Bearing_Clips.stl
o AxleGear.stl
o GearboxShell.stl
o Gears.stl
o GearboxBrushmotor_supports.stl
or
o GearboxBrushlessmotor_supports.stl
- Brush or brushless motor as per source list
- 2x 608 skateboard bearings (22x7x8mm)
- 1x M3x15 Button Hexagon Socket Screw
- 1x M3x10 Cap Hexagon Socket Screw
- 1x M3x30 Cap Hexagon Socket Screw
- Brushless only:
o Pinion gear as per source list / suggested GWS brush motor
comes with pinion gear pre-installed
o 2x M3x4 Button Hexagon Socket Screw / suggested GWS brush
motor comes with suitable mounting screws
11
B O T M O B I L E
Start by re-drilling the holes in the outer gearbox shell and spruce gear.
Drill the spruce gear hole to 3mm (it might be slightly smaller depending on your
printer settings). Test fit the M3x15 Button Hexagon Socket Screw and make sure the
gear can rotate freely on the screw.
Re-drill the spruce gear mounting hole (left hole in the gear shell as shown in the
picture above) with a 2.5mm drill and finally re-drill the right, deeper hole in the gear
box to 3mm.
Apply some grease on the M3x15 Button head screw and screw the spruce gear into
place as shown above. Tighten the screw but ensure the gear can spin freely.
12
B O T M O B I L E
Brushless version: before you install the motor in the motor mount, trial fit the pinion
gear and check whether the flat spot on the motor axle needs to be cut deeper in order
for the screw in the pinion gear to catch properly (was the case in my build).
Next install the motor into the motor mount as shown above (after removing the
supports from printing). Use the M3x4 Button Hexagon Socket Screws if you are
building the brushless version.
For the final assembly, prepare all remaining parts as shown above.
Re-drill the drive gear to 3mm and ensure that it can spin freely on the M3x30 screw.
13
B O T M O B I L E
Insert the M3x30 Cap Hexagon Socket Screw into the gearbox shell from the outside.
Apply some grease to the screw and install the drive gear as shown above.
Place the motor mount onto the outer gearbox shell as shown above (check the
position of the motor pinion gear and adjust its position on the motor axle if
necessary). And secure the 2 parts together with the previous installed M3x30 (tighten
the screw only till it comes out of the other side of the motor mount) in the middle and
the M3x10 Cap Hexagon Socket Screw at the outer end as shown above.
Install the other outer gearbox shell and completely tighten the M3x30 screw.
Carefully check that the gears can spin and adjust of necessary.
14
B O T M O B I L E
Once done, the gearbox assembly should look like the above picture.
For the final step we will combine the main drive gear, axle, axle clips/ retainers and 2x
608 ball bearings with the gearbox assembled in the previous step.
First slide the ball bearings over the axles and push the axles into the main drive gear.
Ensure that both sides have an equal length. Some trimming might be required to get
the axles to fit properly. Ensure a snug fit and apply some CA glue if necessary to
secure the axles in the main drive gear once the length is aligned properly.
15
B O T M O B I L E
Place the ball bearings into the groves in the gearbox and snap the axle clips/retainers
in place.
The axle should now be firmly attached to the gearbox and the main drive gear should
be in constant contact with the gearbox drive gear.
Building the chassis of the Buggy
Prepare the 2 Body halves, interior (brush or brushless variant), 1x M3x7
Button Hexagon Socket Screw and 4x M3x25 Cap Hexagon Socket Screws.
16
B O T M O B I L E
Remove the print supports from the front (RX compartment) and rear (LiPo
compartment on both sides). They should snap off easily.
Above picture shows the front and rear after removal of the supports.
Re-drill the front halve mounting holes with a 3mm drill. Do the same with the single
rear halve interior mounting hole near the gearbox mounts.
Align front and rear halves and secure them in place with the 2x M3x25 screws
17
B O T M O B I L E
Slide the interior into the body shell (from rear to front) and press it in place.
Secure the interior in place with the M3x7 screw
Align the steering assembly and route the servo cable through the gap as shown above
18
B O T M O B I L E
Turn the steering assembly as shown, ensure the servo cable is in the slot and push the
assembly down until it clicks into place
Secure the steering assembly to the body with 2x M3x25 screws. This will help to
reduce the gap between body and steering which comes from slight variations in the
printed parts.
Solder the connectors to the ESC and connect the ESC to the motor
19
B O T M O B I L E
Grip the gearbox firmly with one hand, align the mounting tabs with the rear mount of
the body – ensure that the axle faces the rear of the car – and push the gearbox
assembly firmly in place.
Once in place, it should look like the above
Place the ESC below the gearbox, ensure neither the cables nor the ESC gets in touch
with the spinning parts, and secure it in place with double sided tape. Route the on/off
switch and servo cable to the front.
20
B O T M O B I L E
Install the switch in the slot between the 2 front seats by routing the switch through the
floor space of the left rear seat. Next fit the cable through the narrow gap between the
front seats. The switch can now be pushed downwards and will be securely held in
place.
Use cable ties to secure the motor wires on one side and switch/servo wires on the
other side to the gearbox mount. Make sure that the capacitor from the ESC does not
touch the motor casing.
21
B O T M O B I L E
Final assembly and RC installation
Slide the LiPo into the battery mount and route the cables. A cable tie can be used to
fix the ESC side of the battery connector to the motor leads. The LiPo cable can then
be plugged directly into the ESC connector without the need to fix the LiPo cable to
the body separately
Install your receiver. Use a suitable clip to hold it in place.
Connect the servo cables, clean up the cables with the help of a cable tie and route the
RX antenna.
22
B O T M O B I L E
Assemble the wheels.
Install the front wheels with the “bottom” of the wheels (print surface) facing the
inside, and the rear wheels with the “bottom” facing outside – the square surfaces on
the rear axle will grip into the open part of the rear wheel to drive the wheels.
Prepare the windshield, lamps and steering wheel
23
B O T M O B I L E
Install the windshield by pushing the mounting tabs into the holes in chassis
Use CA glue to glue the lamps and steering wheel in place
24
B O T M O B I L E
!! Congratulations. You are nearly done!!
Charge your LiPo battery (only use a LiPo approved charger), adjust your radio settings
(servo direction, exponential and max travel), program the ESC and take your
Botmobile Dune Buggy 2013 for a spin and do not forget to post a picture of your
creation on Thingiverse (
http://www.thingiverse.com/thing:114784)
☺
25
B O T M O B I L E
Experimental Stuff
Tires:
Pyrophreek requested a model for suitable tires for the care in order to print those in
polyurethane rubber.
The, so far, untested version of the tires is not available for download
(EXPERIMENTAL_Botmobile Tire_Rubber.stl). As this model has not been printed
before, please post your experience with it so I can update this section (especially
whether the threading of the tire prints properly and whether it needs to be scaled for a
tighter fit due to the properties of the rubber).
26
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