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DISCLAIMER: The Barstow School and FRC Team 1939 or any of its members are not responsible for any injuries to any person or damages to any object including the car caused by the modifications. Any type of modification will also void the warranty provided by the manufacturer of the car.

Established in 2006, The Barstow KUHNIGITS is a FIRST Robotics Competition team located at The Barstow School in Kansas City, Missouri. See more about us at: www.frcteam1939.com Our award-winning head coach, Gavin Wood, teaches his students how their STEM skills can help make the world a better place and inspire the youth of today to pursue careers in STEM fields and creates the leaders of tomorrow. In 2015, we began our partnership with Variety KC GoBabyGo Powered by Rockhurst University led by Kendra Gagnon in Kansas City, Mo. GoBabyGo is an international organization founded by Dr. Cole Galloway to provide children with disabilities the opportunity to move independently. Variety KC has generously provided donations to buy all the necessary parts and cars for modification.

The Frozen car from Fisher-Price (LINK) was built and modified as a result of the collaboration between the two parties. Zuhair Hawa and Joey Holliday from The Barstow School led the modification of the car. Sophie Johnson, Miles Knight, George Whitehill, Aasim Hawa and Gavin Wood also helped with the adaptations. The instructions were compiled by Zuhair Hawa and Joey Holliday.

This car boasts a new mechanism for steering that is different from other Frozen car builds. We added a rack and pinion gear system that articulates the wheels. This allows for a joystick to be used instead of the steering wheel. This required our own processor and speed controller attached to the motor. On the outside, we added a PVC exoskeleton that provides the child with cushion and a kickboard to increase back support. You can also add a 5 point harness to add more support.

When completing the project, make sure to keep track of any screws/bolts removed from the car

DISCLAIMER: We are not responsible for any injuries to any person or damages to any object including the car caused by the modifications. Any type of modification will also void the warranty provided by the manufacturer of the car.

Step 1: Gathering Parts and Supplies

Below are the lists of all the parts and tools required for the modifications. Most of these will be found in hardware stores such as Home Depot or Lowe’s, unless otherwise noted. The electronics have hyperlinks directed to the product pages for order. Extra wire can be bought at the local hardware or auto parts store. The internal modifications require skills in soldering, wiring, and programming.

PVC Super Structure:

  • PVC Pipe - ¾”, 10 ft
  • 7" Zip ties (Comes in bags of 50-100)
  • 3/4" PVC elbows - 4 pieces
  • 3/4" PVC t-connector - 2 pieces
  • 1/4” Bolts - 2” long
  • 1/4” Nuts (1 box)
  • 1/4” Washers (1 box)
  • Short, small screws, no longer than 1/2” in length - 1 box (used as set screws to maintain adjustability, PVC can also be glued with PVC glue, but it is permanent)

Steering Mechanism:

  • 1” Wide Flat metal - Aluminium - Usually comes in lengths of 3 - 10 feet, but you only need a small amount.
  • 8/32 Bolts - Various lengths (likely need 10 or fewer)
  • 8/32 Nuts - Nylocks are preferred because the hold better under vibration (for vex parts)
  • 10/32 Bolts - approx. 10 various sizes.
  • 10/32 Washers
  • 10/32 Nuts (Nylocks preferred) - 10 or so
  • 6/32 bolts 1/4 to 3/8 inches in length to mount the motor and the rack gears - approx. 20 pcs
  • Velcro
  • VEX 2-wire 393 Motor:
  • Motor Controller 29:
    • This will relay the signal to the processor
    • You will select this as an option when ordering the Motor
  • Drive Shaft 2”-3” Pack:
  • Shaft Collar (16 Pack):
    • This will make sure the shaft doesn't fall out
    • You will select this as an option when ordering the Drive Shafts
  • VEX Linear Motion Kit (x1)
    • This will be used to drive the wheels from side to side
    • Note that the version used in our build is slightly different from the version that is currently available on the market, but the concept is the same
    • http://www.vexrobotics.com/276-1926.html
  • Nylon Washer Variety Pack:
    • This will enable the correct spacing
    • You will select this as an option when ordering the Drive Shafts

Electronics:

Tools:

  • Measuring Tape/Ruler
  • PVC Cutters (Hack saw can be substituted)
  • PVC Glue
  • Drill
  • Drill Bits - 3/16”, 1/4”, 1/8”
  • Screwdrivers
  • Pen, pencil, or Marker
  • Wrenches
  • Hack Saw
  • File
  • Pliers
  • Wire Strippers
  • Soldering Iron
  • Solder
  • Wire Cutters
  • Wire Crimpers
  • Electrical Tape
<p>My sons participate with team 280. I am going to show them your work. It is really great.</p>
<p>Modifying these cars is actually not part of the FIRST competition. This is just something our team does as a service to the community. FIRST is awesome though. You can check it out here: http://www.firstinspires.com/</p>
<p>What an awesome competition! I'm sure my cousin wishes we could have done this to his Batmobile when we were little. :)</p>

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