9/21/22 Detailed Build Instructions + Building 2nd Guard
Colin Szeto
One of the lock nuts rounded out the walls. Needed to use a vice to hold lock nut in place
In cutting all thread rod, mark out the length of the all thread to cut with tape
Apply WD40 to surface
Cut with dremel
Filing down the cut ends, start at a steep angle. Note all thread is nearly vertical in the photo.
Finish with a shallow angle. Note all thread is nearly horizontal
Utilize vice to hold the sacrificial locknut to bite the threads into the cut end. Connect the opposite end of all threads into the drill. Drill slowly and apply pressure to thread all thread into the nut
Use this setup to place lock nuts in the correct lengths apart from one another
Utilized the back clamp of the motor guard to verify the hole patterns before welding the back rings together
When welding the 6 separate arcs together for the ring, I start with the initial melt at the intersections of each arc. These will create holes as a result of the soldering iron melting and displacing the plastic in the design that will need to be filled with material in the next step. Think of this as making a pilot hole for a drill, we are preparing the material to be welded.
After the initial melted holes (or the pilot holes), use extra filament to melt and fill the holes. This connects the inner support structure together.
However, even after the initial visual indicators implemented into each arch I still welded two intermediate pieces together (Two curves with a single mount holes) This meant that I would have been able to scree the ring onto the interface plate
For future iterations need more specific unique markings between curves to reduce user error
Unwelded the joint to revise my previous mistake. This compromised the structure of the plastic but was able to make up for the undoing of the welding through melting even more plastic onto the joint.
This undoing of the welding joint demonstrates the locations where I began the pilot holes to then fill with plastic in later steps.
