Introduction: Wireless LEGO Race Car Redux

Picture of Wireless LEGO Race Car Redux
The original Wireless Lego Race Car was built with the hacked motor and gearbox with axle that I took out from small toy R/C car, and modified LEGO Plates to be used as a servo mount.
Later on I designed new three new hardwares to be used with custom design LEGO vehicles or robots:
So, I no longer have to hack or modify anything any more. Now it is a lot more convenient, when I have a new custom design LEGO vehicle or robot to build, I just order the 3D printed motor housing and servo mount (since I do not own a 3D Printer!) 

Even though this was a "redux" or a rebuild of Wireless Lego Race Car, there are some changes on the parts. But the shape of the car is still the same.
I am going to show you how to build this car step by step all over again just like we tear the model apart and rebuild it.


Disclaimer:
LEGO®, TECHNIC, are property of The LEGO Group of Companies (http://www.lego.com), which does not sponsor, own, authorize or endorse this creation.

Step 1: Parts & Tools

Picture of Parts & Tools

Following is the list of Lego Technic parts that I used for building this Wireless Lego Race Car Redux.

If you want to do this project you could use the differenct color for the car.

Note: The number in the bracket is the Lego's Design ID.

Lego Components

2 nos. - 1x16 Technic Brick (#3703), Red Color
2 nos. - 1x12 Technic Brick (#3895), Red Color
2 nos. - 1x10 Technic Brick (#2730), Red Color
6 nos. - 1x8 Technic Brick (#3702), Red Color
5 nos. - 1x6 Technic Brick (#3894), Red Color
2 nos. - 1x4 Technic Brick (#3701), Red Color
6 nos. - 1x2 Technic Brick (#3700), Red Color
2 nos. - 1x2 Technic Brick (#3700), White Color
1 no.   - 1X2 Technic Brick with 2 holes Ø4,87 (#32000), White Color (Not shown in the photo)
2 nos. - 1x1 Angular Bricks (#4070)

3 nos. - 2x8 Technic Plate (#3738), Red Color
2 nos  - 2x6 Technic Plate  (#32001), Red Color

2 nos. - 1x10 Plate (#4477), White Color
2 nos. - 1x8 Plate (#3460), White Color
9 nos. - 1x6 Plate (#3666), White Color
2 nos. - 1x4 Plate (#3710), White Color
4 nos. - 1x2 Plate (#3023), White Color
4 nos. - 1x1 Plate (#30008), Yellow Transparent
2 nos. - 1x2x2 Corner Plate (#2420), Red Color
1 no. - 1x4 Flat Tile (#2431)

10 nos. - Connector Peg with Friction (#2780)

4 nos. - Connector Peg 3M (#32556)
2 nos. - Connector Peg with Knob (#4274), Grey Color
4 nos. - Connector Peg/Cross Axle (#6562)
2 nos. -  Connector Peg (#3673)  or 1 1/2 Connector Peg (#32002)

1 no.   - Cross Axle 12M (#3708), Black Color
3 nos. - Cross Axle 6M  (#3706), Black Color
1 no.   - Cross Axle 2M with Groove (#32062), Black Color
1 no.  - Cross Axle 3L with Stud (#6587)

10 nos. - Bush for Cross Axle (#6590)

2 nos. - Lift arm 1x2 thin (#41677), Red Color
2 nos. - Lift arm 3x3 (#32249), Red Color

1 no. - Panel Fairing #5 (#32527), Red Color
1 no. - Panel Fairing #6 (#32528), Red Color

2 nos. - Slanted Brick1x6  (#2744), Red Color

Steering Kit and Gear Kit

1 no. - Steering Gear Holder (#2790)
1 no. - Steering Rack (#2791)
1 no. - Steering Rack Top (#2792)
1 no. - Steering Rack Bracket 1x 8 Plate (#4262)
1 no. - Steering Arm Drop Link (#4261)

2 nos. - 8-Tooth Gear (#3647)
1 no.   - 24-Tooth Crown Gear Type III (#3650)

Wheels and Rims
Front
2 no. - Tire size 30.4 x 14 VR (#6578)
2 no. - Rim, Wheel size 30.4 x 14 VR (#2994)

Rear
2 no. - Tire size 43.2 x 22 ZR (#44309)
2 no. - Reinforced Rim with no pin holes 30.4mm D x 20 mm (#56145)

Rear Wing Flap
1 no. - Panel Fairing #5 (#32527)
1 no. - Panel Fairing #6 (#32528)
2 nos. - Lift arm 3x3 (#32249)
2 nos. - Lift arm 1x2 thin (#41677)

Servo
Servo horn glued to LEGO Cross Axle 3L with Stud (#6587)
9g Micro Servo (Tower Pro SG92R, or T Pro SG90)
3D Printed Servo Mount
(NOTE: The STL file for the servo mount (V01) is available for download here, for latest version (V06) that I used with this Wireless R/C Race you can view the model or have it made at Shapeways, here.)

Motor
2mm Shaft Adapter for Lego Wheels (Pololu part #1001)
(or Modified Connector Peg/Cross Axle (#6562) to fit the shaft of DC toy motor.)
24mm diameter, 9V Motor
3D Printed Motor Housing
(NOTE: The STL file for this motor is available for download here, or in case if you do not have a 3D printer, you can view the model or have it made at Shapeways, here.)

Arduino and Motor Controller IC
Arduino or Arduino compatible (I used Palm Arduino Plus in this project.)
L293D (or SN754410) motors driver IC

Wireless Radios
Palm Arduino Plus has three options of wireless radio modules, 

XBee module, RN-XV WiFly module, and Bluetooth module.

RN-XV WiFly module
Xbee breakout board (for RN-XV WiFly module, I used XB-Buddy Basic Kit, Jameco's Part no. 2163680)

Tools
Super Glue
Sand paper
Files

Step 2: Car Frame

Picture of Car Frame

Following are the photos show how to assemble parts:

Photo 1 Two 1x12 Technic brick (#3895)

Photo 2, 3, 4 Four Connector Peg 3M (#32556) and Two 1x12 Technic Brick (#3895)

Photo 5, 6 Two 1x8 Technic Brick (#3702)

Photo 7, 8, 9, 10 Two 1x4 Technic Brick (#3701), Four Connector Peg (#3673), and Two  Connector Peg with Knob (#4274)

Photo 11, 12, 13, 14 Four Connector Peg (#3673) and Two 1x8 Technic Brick (#3702)

Photo 15 Turn the frame upside down.

Photo 16, 17 One 2x8 Technic Plate (#3738)

Photo 18, 19 One 2x8 Technic Plate (#3738)

Photo 20, 21 One 2x6 Technic Plate  (#32001)

Photo 22 Turn the frame upside down.

Photo 23, 24 One 1x4 Flat Tile (#2431)

Step 3: Steering System

Picture of Steering System

Following are the photos show how to assemble parts:

Photo 1, 2 Steering Gear Holder (#2790) and Steering Rack Top (#2792)

Photo 3 Steering Rack (#2791)

Photo 4, 5 Two Connector Peg/Cross Axles (#6562) and Two Steering Arm Drop Link (#4261)

Photo 6 8-Tooth Gear (#3647)

Photo 7 Servo horn glued to Axle 3L with Stud (#6587).
See details instruction in R/C Lego Car: Step 4 

Photo 8, 9 One 1/2 Bush (#32123)

Photo 10, 11, 12 Connector Peg/Cross Axle (#6562) and Two Tire (Balloon) size 30.4 x 14 VR with rims (#2994)

Photo 13 Now we have part of the steering system done.

Next, we are going to create the decal.

Photo 14, 15, 16 Connector Peg with Friction (#2780) and Two Slanted Bricks 1x6  (#2744)

Photo 17 Instructables Robot sticker.

Photo 18 Mark the cutting line, make the width the same as the width of two slant bricks. Then, draw the number 1 along the cutting line.

Photo 19 Use the X-acto knife to cut the sticker along the marked line.

Photo 20 Remove number 1 from sticker pad, and place on the slant. Then, remove the robot from the sticker pad, and place the robot on top of the number one as shown.

Next, we are continuing on to install the steering system and the front of the car.

Photo 21, 22 1x 8 Steering Rack Bracket Plate (#4262)

Photo 23, 24 Intall the nose with the decal.

Photo 25, 26, 27 Snap the bracket to the steering system. 

Step 4: Servo, Battery Compartment & Motor Housing

Picture of Servo, Battery Compartment & Motor Housing

New parts:
3D Printed Motor Housing. See design details in Step 1 of R/C LEGO "The Bull" Buggy
Modified Connector Peg/Cross Axle (#6562) to fit the shaft of DC toy motor. (or used Pololu part #1001, as I used in this project.)

Following are the photos show how to assemble servo mount:

Photo 1, 2 Remove the front 2x6 Technic Plate (#32001) from the car body.

Installs 9g servo into 3D Printed Servo Mount.

Photo 3 9g Micro Servo (Tower Pro SG92R) and 3D printed servo mount.

Photo 4 Insert the cables from the servo into the top opening of the servo mount.

Photo 5 Slide the servo into the 3D printed servo mount.

Photo 6 Push the servo in until the mounting area flush with 3D printed servo mount.

Photo 7, 8, 9 Four 1x4 Plate (#3710)

Photo 10, 11, 12 Place the assembled servo in place, as shown in the photo.

Photo 13, 14 Two 1x2 Plate (#3023)

Photo 15, 16 Two 1x1 Angular Bricks (#4070)

Photo 17, 18, 19 Place the removed 2x6 Technic Plate (#32001) back to it place.

Photo 20, 21 2x6 Technic Plate (#32001)

Photo 22, 23 Two 1x2x2 Corner Plate (#2420)

Photo 24, 25 Two 1x6 Plate (#3666)

Photo 26, 27, 28 Four 1x1 Transparent Plates (#30008)

Photo 29, 30 Two 1x6 Technic Plate (#3666)

Photo 31, 32 Two 1x8 Technic Plate (#3460)

Photo 33, 34 Two 1x8 Technic Brick (#3702)

Photo 35, 36 Two 1x2 Technic Bricks (#3700)

Photo 37, 38 Rechargeable 7.4V 500mAh LiPo Battery power supply for motor.

Photo 39. 40 Rechargeable 3.7V LiPo Battery power supply for Arduino and XBee/RN/XV WiFly or Bluetooth module.

Photo 40, 41 Assembled 3D printed motor housing with 24mm diameter 9V motor.


Step 5: Rear Wheels

Picture of Rear Wheels

New Lego parts:
24-Tooth Crown Gear Type III (#3650)

Following are the photos show how to assemble parts:

Photo 1, 2 Cross Axle 12M (#3708), and 24-Tooth Crown Gear Type III (#3650)

Photo 3, 4  Bush for Cross Axle (#6590)

Photo 5, 6  Two 1x6 Technic Bricks (#3894)

Photo 7, 8 Two Tires (Balloon) size 43.2 x 22 ZR with rims (#56145)

Photo 9, 10 Two 1x6 Technic Bricks (#3894)

Photo 11, 12 1x6 Technic Bricks (#3894)

Photo 13, 14 Installed the wheelbase to the main body of the car.


Step 6: Rear Wing Flap

Picture of Rear Wing Flap

Following are the photos show how to assemble parts:

Photo 1, 2, 3 Cross Axle 6M  (#3706) and two Lift arm 1x2 thin (#41677)

Photo 4, 5, 6 Two Lift arm 3x3 (#32249) and Cross Axle 2M with Groove (#32062)

Photo 7, 8 Two Bush for Cross Axle (#6590)

Photo 9 Two Cross Axle 6M  (#3706)

Photo 10, 11 A Panel Fairing #5 (#32527), A Panel Fairing #6 (#32528), and two Connector Peg (#3673)

Photo 12, 13, 14 Two Bush for Cross Axle (#6590)

Photo 15, 16 Two 1x6 Technic Bricks (#3894)

Photo 17, 18 Install the flap to the car from previous step.


Step 7: More Car Frame

Picture of More Car Frame

Continue from the previous Step (7):

Photo 1 Car from previous Step.

Photo 2, 3 Two 1x2 Technic Bricks (#3700)

Photo 4, 5 2x6 Technic Plate (#32001)

Photo 6, 7 Two 1x2 Technic Bricks (#3700)

Photo 8, 9 Two 1x10 Plates (#4477)

Photo 10, 11, 12 Palm Arduino Plus with Bluetooth module installed, and Two 1x6 Plate (#3666)

Photo 13, 14 Two 1x2 Plate (#3023)

Photo 15, 16 Three 1x6 Plate (#3666)

Photo 17, 18 1X2 Technic Brick with 2 holes Ø4,87 (#32000)

Photo 19 And we have the car! Bravo!

Step 8: User Interface and Control

Picture of User Interface and Control

From this point on, everything is the same as what I did in original version of Wireless Lego Race Car from Step 10 to 12.

Step 10: User Interface Design 
Step 11: RN-XV Module Configuration 
Step 12: PHP and Apache on Mac OSX 

If you want to try out using XBee module instead, please see the the details in R/C Lego Car, Step 9: Processing UI & Arduino Sketch.

For the Bluetooth connection, see the details of how to configure the Bluetooth at this site:
Setting up a Wireless serial connection with your Wiring hardware using Bluetooth and
BlueSMiRF Installation Tutorial by James Frye.

Since both XBee and Bluetooth communication are Serial Comm. you could use the same codes that we used in with R/C Lego Car (& Redux) with the minimum change of codes.

To used bluetooth you need to change the Baudrate to 115200 in both Arduino Sketch and Processing Sketch, instead of what we set for XBee. (As shown below.)

In Arduino Sketch




In Processing Sketch



You can use the same code that is used with LEGO R/C Car Redux, and can be downloaded in Step 11: Processing UI & Arduino Sketch.

Step 9: Conclusion

Picture of Conclusion


Photos and Videos

Below are some photos of finished Wireless LEGO Race Car Redux, and videos shows the bench test of Lego Race Car with XBee module.

Videos

- Test Servo

- Test Motor 


Comments

www139 (author)2013-08-11

where did you get the motor and controller? I didn't know they made those pieces!

sath02 (author)www1392013-08-12

I got the motor from e-bay.

For the Palm Arduino Plus (DIY Arduino with motor controller on the PCB) is the prototype that I designed specifically to use with LEGO components.
I got it made from third party fabricator (OSH Park, http://oshpark.com.) the EagleCAD files provided at Palm Arduino Plus here, https://www.instructables.com/id/Palm-Arduino-Plus/.

By the way, I have some extra motors that I can sell to you. Sent me Private Message.

hawk45 (author)2013-08-11

Ok I like knex better than leogs but this is awesome!

sath02 (author)hawk452013-08-11

I have never tried K'NEX yet! But I am going to try it someday.
Thanks. :)

S.Korea (author)2013-08-01

Hmmmmmm, how much does it cost???

sath02 (author)S.Korea2013-08-01

This is my rough estimate:
LEGO components, based on LEGO's Pick-A-Brick shop (http://shop.lego.com/en-US/Pick-A-Brick-ByTheme) and BrickLink.com (http://www.bricklink.com).
The components are also mixed between the used and new from both places, and the price is for USA only. You might get it cheaper in other country.
I got it around US$ 27.00.

9g Micro servo is around US$ 6.00
2mm Shaft Adapter is US$ 3.00 from Pololu.
9V 24mm Motor is around US$ 2.00 from ebay.

3D printed servo mount is around US$ 6.00 from Shapeway.
3D printed motor housing is around US$16.00 from Shapeway.

You will also need Arduino, some where from US$5 to 25, depend on whether you are doing it yourself or you are buying the ready made.

And you will need wireless module, either Bluetooth, XBee module, or RX-XV Wifly module.
Bluetooth is from US$ 5.00 from ebay to $40.00 brand-name buletooth.
XBee modules (you probably need two, and it is around US$ 26.00 each.
If you use RN-XV WiFLY module it is around US$ 35.00.

All the price quoted above are not included Shipping and Handling.

Hope this answer your question!



CJR2115 (author)2013-07-30

AWESOME

sath02 (author)CJR21152013-07-31

Thanks.

BABLOON1424 (author)2013-07-31

It's very gshushsgxtsnu and it makes me feel shsbsysjs

WWC (author)2013-07-30

Very nice.

sath02 (author)WWC2013-07-30

Thanks.

About This Instructable

12,471views

95favorites

License:

Bio: I am Electronic Visualization Artist. I look at things through the Looking Glasses.
More by sath02:"Fortune Frog" Money ClipR/C LEGO "Coaster" DroidR/C LEGO 'Velocipede' Droid
Add instructable to: