To make 100 style BUMPERS

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How to make 100 style BUMPERS Bumpers Bumpers should: NOT FALL OFF Have tight & smooth fabric all over Display numbers CLEARLY and NEATLY Be easily interchangeable Follow the rules! All outside corners protected with >8 in. on each side of corner Each set weigh <20 lbs. Plywood: ¾” thick, 5” tall

Use 2, 2 ½ in. round, petal, or hex “pool noodles” Cushion material may extend up to 2 ½ in. beyond the end of the plywood. To assist in applying the fabric covering, fasteners may be used to attach the pool noodles to the wood backing, so long as the cross section of Figure 4-8 is not significantly altered (e.g. tape compressing the pool noodles). They should be the same all around, not some solid some hollow. Screen Shot 2014-12-02 at 6.54.37 PM.png

How to make “100 style” one-piece Bumpers Measure robot, Cut Wood Measure frame in person (not CAD) Add ¼” to side pieces Add 1 ¾” to front and back pieces Mark ¾” plywood with correct dimensions Cut wood on bandsaw/table saw/jigsaw

Mounts and Attachments Determine desired bumper height from ground and cut 2x4’s to that height (as placeholders) Temporarily clamp on bumper mounts to robot frame and set bumper side pieces on holders Mark center of holes to line up with mounts Drill holes to fit 3/8” Tee Nuts and hammer them in on inner side of wood From outer side, screw in 3” long 3/8” bolts Check fit on robot for both sets of bumpers, then match drill and rivet bumper mounts to robot frame IMG_0518.JPG 3. Glue Frame & add Brackets Set up wood frame in correct configuration on flat surface Wood glue corners: opposites first Use spare pieces of 2x2 tubing to clamp 2 pieces together at corner and wait 10 minutes Remove clamps, match drill pilot holes for outer L brackets Screw in L brackets with short wood screws Repeat d. & e. one corner at a time 4. Check fit with mounts Put both bumper frames on robot Use pins, check everything If too tight, start over or file wood If too loose, add extra support pieces on front and back at very end

5. Noodles! Set up noodles against frame Cut corners at 45o angles (careful of rotation) Apply hot glue to wood then attach noodle Cut of sharp corners (keep 2.5” rule!) Add noodle wedges to corners, if needed DSC_1006.JPG

6. Cut Fabric (4 pieces per color) Dimensions: outer length with noodles plus 5”. 15” wide. Lay out fabric and mark back side with pencil or chalk and draw straight lines Using sharp fabric scissors cut along drawn lines

7. Put on Numbers (before upholstering) Measure center of fabric and draw cross (lightly on front) Put in embroidery frame and use embroidery machine Use basic fonts, white thread, and ½” wide #s 7. Put on Numbers (before upholstering) Measure center of fabric and draw cross (lightly on front) Put in embroidery frame and use embroidery machine Use basic fonts, white thread, and ½” wide #s 9. Upholstery (Staple and Secure) Adjust fabric to correct height/orientation, align seams with corners Begin stapling 4 corners on top then flip and do bottom 4 corners – wrap and cut fabric as shown Staple rest of fabric to wood evenly and smoothly along edges (not top and bottom), avoiding puckering/bubbles Hammer in staples until flush with fabric Trim excess fabric and check fit

 on robot

10. Cover Inside Face of Wood Cut extra fabric rectangles with same fabric from before to exact size of inside face (cut holes for bolts, too) Apply contact cement to bumper and fabric to adhere the two. Smooth out ALL bubbles and imperfections IMG_5937.jpg


Supplies:

  • 4x8 plywood ¾ in
  • Fabric
  • 8 noodles per bumper
  • Vinyl stickers
  • Staple gun
  • Staples
  • Mounts
  • Hot glue/gun
  • L brackets