Now that your laser cut is ready, it's time to assemble TJBot. Folding the chipboard requires patience and your full attention! :-)
Make sure you set aside enough time for folding TJBot and don't rush. It's easy to make a mistake by folding the chipboard in the wrong direction, and reversing the fold will cause the chipboard to break off. Don't panic if this happens, as you can use scotch tape to repair the damage.
Please note that when folding the chipboard, the following tricks are helpful.
- Use the edge of a table or a metal ruler to give yourself leverage when folding the seams
- Don't overfold – use the smallest amount of pressure needed to make the seams start moving, but stop just when they start to give. If you use too much pressure, you may tear the seam.
- Plan your folds – as the saying goes, "measure twice, cut once", make sure you are folding in the right direction before you begin your fold.
The following videos show an overview of how to fold the chipboard and assemble TJBot.
Begin by laying the chipboard on a flat table.
The first step is to fold TJBot's jaw. The jaw piece is the large one with the four "Fold Down" tabs at the corners. Pop it loose from the larger piece of chipboard.
Fold down the corners that say "fold down".
Next, fold down the rectangular piece connected to the "Fold Down" tabs. This will make a square shape between the rectangular pieces and the "Fold Down" tabs.
Now, fold down the other two rectangular sides. Fold the inner seam first.
Then fold the outer seam over the "Fold Down" tabs and punch down the little tabs into the holes to finish the section.
Congratulations, you've assembled TJBot's jaw! Set it aside for now.
Next up are TJBot's legs. Pop the two legs loose from the chipboard. The legs have long rectangular pieces with "Fold Up" and "Fold Down" written on them.
The legs are the most delicate pieces in the set and require patience and focus. Begin by folding the piece that says "Fold Up" in the upward direction. Next, fold down the piece that says "Fold Down". We have found it to be easier to fold the "Fold Up" piece first and then fold the "Fold Down" piece.
Now, insert the legs into the jaw. The legs go into the L shaped holes in the jaw until the "Fold Up" piece hits the base.
Insert the legs from the top of the jaw downward. It may take some force to push the legs through the holes.
Next, remove the leg brace.
The brace sits in the two rectangular holes in the legs underneath the jaw. It keeps the legs straight.
Now, remove the feet and place them before you as shown below.
Fold the side flaps downward (in the direction of the table), very weakly. The feet will form a triangle shape that attaches to the legs, so over folding may cause them to break.
Insert the feet into the notches in the leg as shown below.
Congratulations, you can now make TJBot stand on his own! You are now halfway through with the folding. :-)