Tom's Life Bits

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Instructor’s Note:

This class is about a design that can be altered to fit different needs.  This 
will be discussed in class.  The materials used in this version of the design 
are included below.  These are not, however, the only options for lengths, sizes 
and even materials.

For class the instructor will be mounting a 1.75 lb foam Terminator head to the 
top of the mechanism. This head is not available to the public and is used only 
as a demonstration (because it looks REALLY cool).  You do not need to have a 
head to mount to the mechanism in order to take the course.

The servo motors listed for the class are very powerful and fairly expensive, 
but if you do not plan to mount a heavy object to the mechanism, less powerful 
(and less expensive) servo motors may be substituted.  If a heavier head is 
mounted, stronger servos may be required.

We will also cover several options for controlling the motors.  If you do not 
have or wish to purchase an RC radio then we will cover an option that allows 
the servos to be driven by using three servo testers.  We will also touch 
briefly on controlling them via a programmable board such as Arduino and Polulu. 
We will also demonstrate how to use the same basic design to puppeteer a head 
manually.

VENDORS

Here are some vendor that carry the items you’ll need.  You may also be able to 
find some of the items at your local hardware store or hobby shop.

Online Vendors

McMaster Carr – large selection of hardware, tools and metal

Servo City – selection of RC parts, hardware and prefabricated servo brackets

Tower Hobbies – large selection of RC parts

Robot shop – selection of RC parts, hardware and prefabricated servo brackets

Amazon – selection of almost everything
Los Angeles Vendors
(local vendors used often):

Industrial Metal Supply – metal

Robin’s Hobby – RC parts
Original Manufacturers

Instructor’s note – use these sites if you are having trouble finding a vendor for their product.

K and S Precision Metals – list of hobby brass distributors

Ruland – list of shaft collar and coupling distributors

Lovejoy – list of universal joint distributors

Du-bro – list of  RC part distributors
SUPPLIES

Instructor’s note:  McMaster Carr numbers below are provide for easy reference. 
McMaster may not ship to you if you are out of the country and you may have to 
find the equivalent locally or on Amazon.

METAL

¼ inch thick x 1 ½ wide aluminum bar (1 foot length) – McMaster #8975K518

1/8 inch thick x 2 inch wide aluminum bar (1 foot length) – McMaster #8975K582

3/8 inch thick x 2 inch wide aluminum bar (6 inch length) – McMaster #8975K59

¼ aluminum rod (6 inches) – McMaster #8974K22

1/16th inch thick x ¼ wide hobby brass strip (K and S Precision Metals brand) (Need 1 foot)
MOTION COMPONENTS

¼ inch stainless steel shaft (6 inches) – Mcmaster #1257K65 (also available from ServoCity)

¼ inch clamping shaft collar (Ruland brand) (need 2) – McMaster #6435K12 (also available from ServoCity)

¼ inch extra gripping shaft collar (Ruland Brand) (need 1) – McMaster #9951K31

¼ inch two piece clamping shaft collar (Ruland brand) (need 2) – McMaster #6436K12

¼ inch steel rod ends with female shank (need 2) – McMaster #60645K321

¼ inch pin and block universal joint (Lovejoy brand) (need 1) – McMaster 
#6443K24 (also available from ServoCity if you are on a tight budget – not 
Lovejoy brand)

¼ outer diameter female 6-32 threaded round aluminum stand offs – 3 inch long 
(need 2) – McMaster #93330A542 (also available from ServoCity)

6-32 heavy duty RC ball linkage (DuBro brand) (need 4) - Available at most RC suppliers

4-40 heavy duty RC ball linkage (DuBro brand) (need 2) – Available at most RC suppliers
HARDWARE

2-56 by ¼ inch long button head cap screws (need 8)

4-40 by ¼ inch long socket head cap screws (need 2)

4-40 by 3/8 inch long socket head cap screws (need 3)

4-40 by ½ inch long socket head cap screws (need 4)

4-40 “all thread” stainless steel threaded rod (need 1 piece) – Available at ServoCity and most RC Suppliers

6-32 by 3/8 inch long button head cap screws (need 16)

6-32 by ½ inch long socket head cap screws (need 8)

6-32 by ½ long set screws (need 4) – OR - 6-32 “all thread” stainless threaded rod (need 1 piece)

¼ -28 by ½ inch long button head cap screws (need 2)
RC COMPONENTS

Servo Brackets – Standard Servo Plate B (Actobotics brand) (need 3) - Available from ServoCity

RC Servos (need 3) – (we will be using Hitec HS5645MG servos but others may be 
substituted depending on project specifics) - Available at most RC suppliers

RC receiver – at least 3 channels (need 1) – available at most RC suppliers
RC COMPONENT CONTROL OPTIONS

OPTION A:

4 channel RC Radio that matches receiver (need 1)

OPTION B:

RC Servo / ESC Tester (Huituo Electronic brand) (need 3) Available from RobotShop and other RC suppliers

6 inch RC servo extension cables (need 3) – available at RC suppliers

Small Wire nuts (need 3) or electric tape

Wire strippers
RC POWER OPTIONS

OPTION A:

6 volt rechargeable RC battery pack

RC battery pack charger

OPTION B:

6 volt dc output plug in power supply (need 1)

Volt meter

Wire strippers

Small wire nuts or electric tape

6 inch RC servo extension cable
HAND TOOLS

Allen wrench set - .050 thru 5/16 – ball ends preferred

Drills – ¼ inch, #50, #41, #43, #30, #36, #25 (these are tap and clearance drills for 2-56, 4-40, and 6-32 respectively)

Taps (2-56, 4-40, 6-32)

Tap handle

Counter sink

Small Philips head screwdriver (for servo horn)

Razor blade or exacto knife

Diagonal cutting pliers

Tape measure or ruler
OPTIONAL HAND TOOLS
(helpful but not absolutely necessary)

Digital Calipers

Automatic punch

Small table vice

Small clamps

Metal file
ELECTRIC TOOLS

Aluminum cutting tool - band saw, jig saw or hack saw (instructor will be using a band saw in class)

Aluminum drilling tool - drill press or drill motor (instructor will be using both in class)

Aluminum shaping tool – belt or disc bench sander or rotary tool with sanding drum (instructor will be using sander in class)
MISC SUPPLIES

Double stick tape or sticky back velcro

Medium strength and high strength “Loctite” thread lock (optional)

Tapping fluid or lubricant

Wooden block (or similar) to use as a drilling surface

Sandpaper (optional)

Epoxy or epoxy putty (optional – used to attach head to mounting plate)

RC on/off switch (optional)

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