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Step 8Final Trim Items, Cube Attachment, and Test Assembly
1. Bottom Skirt. Next we'll prepare a metal skirt to go around the three "leg" bolts located at the underside of the base plate. Cut a band of aluminum band about 44 mm wide and 27 inches long.
2. Apply poster mount putty to the outside portion of the three 1/4-20 bolts that serve as base plate legs. Wrap the aluminum strip into a nice circular shape around the 3 bolts - the putty will help the strip stick to the legs.
3. Where the strip ends join, use a large paper clip and aluminum tape to fasten the ends together. You will also need to cut an opening in the strip large enough to accommodate the power supply jack and on/off switch or RS-232 cable depending on which controller you're planning to use (see photos).
4. Bottom Disk. The bottom disk sits inside the glass cylinder resting on the heads of the 3, 8-32 rubber grommet mounting screws. Its job is the hide the screws and help create the appearance on a solid disk at the bottom of the glass cylinder.
5. Cut a aluminum disk with an outside diameter (OD) sized to fit inside the cylinder about 1 inch in from the open end. The disk inside diameter (ID) should be about 1/2 inch, it does not have to be perfectly centered as the cover washer (described below) will hide any off center errors..
6. Then cut a cardboard disk about the size as the aluminum disk and glue the two disks together - the cardboard just serves to stiffen the aluminum disk.
7. Cover Washer. The Cover washer goes over the drive shaft below the wax Intersect Cube and rests on the top of the Bottom Disk described above. Cut from aluminum strip stock a washer with 1" OD and 3/16" ID. Its job is just to mask any not quite centered errors between drive shaft and the bottom disk.
8. Attach Wax Intersect cube to Drive Shaft. First assemble the cylinder to the base plate and measure the distance (D1) from the base plate up the upper edge of the bottom 22 mm wide aluminum band you attached to the cylinder in Step 6. Next measure the distance (D2) from the base plate up the lower edge of the top 22 mm wide aluminum band.
Now remove the glass cylinder and and install the drive shaft on the motor and hold the drive shaft straight up. Mark the locations D1 and D2 (measured from the base plate) on the drive shaft. The wax cube should be centered half way between the D1 and D2 marks, this will center it in the "window" of the glass center created by the top and bottom bands.
10. Important - Before you glue the Wax cube in place. Slide the cover washer onto the drive shaft so that is rests on top of the drive shaft heat shrink tube coupler and below the final location were the wax cube is attached to the drive shaft (see photo). Glue the wax cube to the drive shaft using white epoxy - let sit overnight to fully cure. Finally, paint the exposed portions of the drive using a black magic maker.
11. Test fit Assembly. After the epoxy cures assembly the cube/drive shaft, bottom disk, and glass cylinder onto the base plate to make sure it all fits together as it should.
It can be a little tricky to get the top of the shaft fit into the nylon bushing, but by carefully tilting the glass tube and base plate assembly back and forth you should be able to get it assembled OK.
If you're really struggling ,you can loosen the motor mount nuts enough to drop the motor way down - this will allow the glass cylinder to be fully seated against the base plate, you can then grab the motor to move the drive shaft up and into position.
After test fitting everthing together, you can now dis-assemble to make it easier to complete the controller assembly on the bottom side of the base plate. Once that's done just re-assemble one final time.
2. Apply poster mount putty to the outside portion of the three 1/4-20 bolts that serve as base plate legs. Wrap the aluminum strip into a nice circular shape around the 3 bolts - the putty will help the strip stick to the legs.
3. Where the strip ends join, use a large paper clip and aluminum tape to fasten the ends together. You will also need to cut an opening in the strip large enough to accommodate the power supply jack and on/off switch or RS-232 cable depending on which controller you're planning to use (see photos).
4. Bottom Disk. The bottom disk sits inside the glass cylinder resting on the heads of the 3, 8-32 rubber grommet mounting screws. Its job is the hide the screws and help create the appearance on a solid disk at the bottom of the glass cylinder.
5. Cut a aluminum disk with an outside diameter (OD) sized to fit inside the cylinder about 1 inch in from the open end. The disk inside diameter (ID) should be about 1/2 inch, it does not have to be perfectly centered as the cover washer (described below) will hide any off center errors..
6. Then cut a cardboard disk about the size as the aluminum disk and glue the two disks together - the cardboard just serves to stiffen the aluminum disk.
7. Cover Washer. The Cover washer goes over the drive shaft below the wax Intersect Cube and rests on the top of the Bottom Disk described above. Cut from aluminum strip stock a washer with 1" OD and 3/16" ID. Its job is just to mask any not quite centered errors between drive shaft and the bottom disk.
8. Attach Wax Intersect cube to Drive Shaft. First assemble the cylinder to the base plate and measure the distance (D1) from the base plate up the upper edge of the bottom 22 mm wide aluminum band you attached to the cylinder in Step 6. Next measure the distance (D2) from the base plate up the lower edge of the top 22 mm wide aluminum band.
Now remove the glass cylinder and and install the drive shaft on the motor and hold the drive shaft straight up. Mark the locations D1 and D2 (measured from the base plate) on the drive shaft. The wax cube should be centered half way between the D1 and D2 marks, this will center it in the "window" of the glass center created by the top and bottom bands.
10. Important - Before you glue the Wax cube in place. Slide the cover washer onto the drive shaft so that is rests on top of the drive shaft heat shrink tube coupler and below the final location were the wax cube is attached to the drive shaft (see photo). Glue the wax cube to the drive shaft using white epoxy - let sit overnight to fully cure. Finally, paint the exposed portions of the drive using a black magic maker.
11. Test fit Assembly. After the epoxy cures assembly the cube/drive shaft, bottom disk, and glass cylinder onto the base plate to make sure it all fits together as it should.
It can be a little tricky to get the top of the shaft fit into the nylon bushing, but by carefully tilting the glass tube and base plate assembly back and forth you should be able to get it assembled OK.
If you're really struggling ,you can loosen the motor mount nuts enough to drop the motor way down - this will allow the glass cylinder to be fully seated against the base plate, you can then grab the motor to move the drive shaft up and into position.
After test fitting everthing together, you can now dis-assemble to make it easier to complete the controller assembly on the bottom side of the base plate. Once that's done just re-assemble one final time.
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