Have you ever wanted your own personal robot to do your bidding, take over the world, or just to play with, wait on longer, it's time to start making. After making this robot with what I call friction hinges, they worked so well I went to design several other bigger and better projects with them. I hope this will inspire you to try some of your own variations. Have fun make your own army or whatever...
Step 1: Getting Started
First download the file, cut out this robot, it was designed for 3 mm ply. Besides the 3 mm ply you will need some glue, a few toothpick, a piece of sandpaper (fine grit will work best), small hammer, and a pair side cutting pliers. Lastly you are going to need a handful bamboo skewers about 10'' long. Measure the skewers with the caliper and find what size the holes need to be and change them, or maybe your skewers will be right size and will fit the holes provided. Click on the out box around the parts it should measure 245 mm x 180 mm if it doesn't size it to fix those dimensions select all in the box and re size it. there is a section that is on a green layer, it's some graphics you can substitute if you want, you might want to show you robot has a heart. Depending on the skewers you get you might have to use some calipers to measure them and resize the hole to match, remember to measure several to get an average because you want to make sure that they are a tight fit and they are all just a little different.
Step 2: Head Assembily
Find these six pieces that make up the head and glue them together to make the cube for the head. Please feel free to design your face or even leave it blank, just change layers file before cutting.
Step 3: Body Assembily
These are the pieces that make up the body, it's important to make sure that the holes on the side pieces are both at the top, and the top piece has the single hole and the bottom has the two slots. The chest piece has a door that is cut out if you want to have a secret compartment in your robot, but if you don't just change the color of the line to the layer that just draws lines and not cuts all the way through.
Step 4: Feet Assembily
The feet are simple just glue as shown, but they are suppose to be a tight fit so use a small hammer to make sure that they fit flush together.
Step 5: Sanding
There a few piece that you will see both sides and if your laser is like mine then you get scorch marks on the back so sand them before assembling.
Step 6: Arms Assembily
(Note no glue is to be on any of the skewered pieces, when after playing awhile they loosen up just pinch them back together to tighten back up.) Take a skewer and place a washer, then a shoulder pad, upper arm, another shoulder piece, then push the skewer through the body, shoulder, upper arm, shoulder piece and finally a washer. Flush cut the skewer and sand. Next lower arm assembly washer, lower arm, upper arm, end with lower arm. There's not a washer on this side so there is body clearance. Clip and sand check the photos to see if they match.
Step 7: Leg Assembly
Place skewer through the holes following the layout in the photo. Clip and sand. Glue the leg to the body and it you see a gap hammer the foot on until flush with the body.
Step 8: Head
Now place skewer through a washer, then the head and out the other side, then clip leave about a 1/2 inch neck, now place it on his shoulders and your done.
Step 9: Let's Play
Make more than one so they will have a friend to play. They great posers so place them around holding and doing things. Irobots are great for stop motion videos. Have fun and be creative...