Step 2: Making the Base
To start off, I have done most of the work for you! YAY. That would include a couple months of resaerch and design for this project, which should be done for any robot you plan to build your self after this. I made a scale 3D model of Walbot in a free program called SketchUp by Google (thank you Google), you can download my model of walbot from Google 3D warehouse here (note: there might be some differences in the motor type and some of the components are missing like the circuit shield on top of the Arduino, wires... I will update the model when I have time).
Step 1: Download the Word document of the cutting and drilling guide here, and print it out. Once it is printed make sure that it is 6" wide by 5.5" long. Now cut off the extra bottom half of unprinted on paper so that you have a template thats about 8 1/2" by 6", and using some kind of adhesive or semipermanent glue or double stick tape, mount both the templates on the Lexan sheet.
Step 2: Cut out the Lexan base with the bandsaw, following the template line as closely as possible. To make it easier, cut little relief slit along the perimeter to free up the area you are working on without having to worry about the blade binding up. When your finished, you can use some sand paper to smooth out the edges if your cuts did'nt come out perfect.
Step 3: Over at the drill press, use a #29 drill to make the holes for the 8-32 standoffs, and a #43 drill to make the holes for the 4-40 screw size motor bearing blocks and standoffs for the Arduino. When drilling be sure to use a little WD-40 or water as a lubricant to keep the polycarbonate (Lexan) cool.
Optional: it is not on the template, but to make things neater, if you have a large 1" forstner bit or other big drill bit, it is useful to drill a hole right where the two lines cross on the TOP layer. This allows an area to channel wires from the top layer to the bottom layer. I did it on mine and that is what you will see in the picture, but it is not necessary.
Step 4: Using the 4-40 tap you bought in the set, carefully tap the holes that you drilled with the #43 drill. Then using the 8-32 tap do the same for the 3 holes you drilled for the standoffs with the #29 drill. If you do not know how to thread materials with a tap, learn how to here. I use a cordless drill, but it is not recommended if you are just a beginner.
Step 5: Using goo gone or other adhesive remover, remove the drilling and cutting templates and wash the lexan free of all fingerprints and grease.