Step 6: The 1st Goal: The Extreme Traxxas E-Maxx Modification

Now for the mechanical work on the extreme remodeling of the Traxxas E-Maxx:

0. Necessary tools and materials:
      - Laser CNC router or Plasma CNC router
      - Aluminum plate - size 1200x600x3mm (Form main chassis base and for the beams)
      - Aluminum plate - size 400x400x1mm (For servo casing, Arudino casing, LED support, etc)
      - Bolts - 100 units of 3mm (3M)
      - Nuts - 200 units of 3mm (3M) (2 nuts per bolt  for extra holding force)
      - Several different sized screw drivers
      - Several different sized pliers
      - Metallic file (to trim the aluminum borders)
      - Some sandpaper (for aluminum finishing)
      - Paper face mask ( to avoid inhaling aluminum dust (highly toxic) )
      - Some transparent aluminum varnish spray (for painting the aluminum to avoid
         aluminum oxidation)

1. Cut out all the necessary aluminum parts form the aluminum plate (see photo of
     all aluminum parts):

       1.1 - Parts for holding/fixing the Arduino on board (see photos for more detail)
       1.2 - Parts for holding/fixing the EeePC (see photos for more detail)
       1.3 - Parts for holding/fixing the Pololu Micro servo Controller (see photos for more detail)
       1.4 - Parts for holding/fixing the LED's (see photos for more detail)
       1.5 - Parts for holding/fixing the 3.5G/4G Modem (see photos for more detail)
       1.6 - Parts for holding/fixing the 2 micro servos and 1 boom camera servo
       1.7 - Parts for holding /fixing the Aluminum beams (see photos for more detail)

2. The aluminum base plate:
       2.1 - Download the 2D design here: http://dl.dropbox.com/u/4302919/chassis_v15.cdr.
       2.2 - Cut the aluminum plate using a laser CNC router.
       2.3 - The design needs to be laser cut or Plasma CNC router or Laser CNC router.
       2.3 - All small holes have 3mm diameter for allowing the bolts to fit.
       2.4 - The center square hole in the middle of the plate is made in order to allow for the
                motors to fit in between and lower the center of mass.
       2.5 - The 4 small rectangular holes are for allowing cables to pass from one side of
                the plate to the other.

3. The 4 aluminum beams:
       3.1 - The aluminum beams allow for the protection of the electronic equipment
                on-board the vehicle .
       3.2 - The aluminum beams fit perpendicularity to the aluminum plate.
       3.3 - The beams fit on the front and back of aluminum base  (see photos)

4. The 2 "boom camera" aluminum beams:
       4.1 - The 2 beams are screwed together spaced with 2.5cm apart (to create a
                steady structure and to avoid propagation of vibration to the web camera)
       4.2 - The camera is mounted on the end of the beams
       4.3 - The boom camera beam is mounted on the rotary motor extension
       4.4 - Because it is a moving part the beam has 2 docking stations, one in the
                front and one in the back of the aluminum plate to allow the arm to rest

5. The pan tilt system:
       5.1 - The pan tilt system is composed by 2 servo motors (see photo)
       5.2 - The servos are mounted one on top of each other using small aluminum
                cases (see photo)

6. Mounting the base aluminum plate to the aluminum beams:
       6.1 - Mount the aluminum plate on board the vehicle.
       6.2 - Isolate the center square hole with rubber to avoid the motor discharging on
                the aluminum
       6.3 - Tighten with bolts all the necessary aluminum parts in order to hold the
                on-board Arduino.
       6.4 - Mount the Arduino board on-board the vehicle.
       6.5 - Tighten with bolts all the necessary aluminum parts in order to hold the
                on-board computer (EeePc 901).
       6.7 - Mount the on-board (EeePc 901) computer on the vehicle.
       6.8 - Tighten with bolts the 4 protective aluminum beams

7. The boom camera motor system (this is the most complex mechanical aspect of the
     mechanical work, see photos for more detail)
       7.1 - Mount the boom camera motor inside a aluminum case and attach a cylindrical
                extension inside 2 aligned bearings
       7.2 - Attach the aluminum beams to the center of the cylindrical motor extension

After all the motors are attached inside of the aluminum casings make all the wire
connections mentioned in the previous step.