MakerBot Botmobile Dune Buggy 2013 User manual

M A K E R B O T
Botmobile Dune Buggy 2013
Assembly Manual

Table of Contents
Tools & Part List ....................................................................... 1
Tools & Consumables .............................................................. 1
RC Components ....................................................................... 2
Printing the parts ...................................................................... 5
Print Settings ............................................................................ 5
Assembly ................................................................................. 8
Steering assembly .................................................................... 8
Gearbo & Rear A le ............................................................. 11
Building the chassis of the Buggy ........................................... 16
Final assembly and RC installation ........................................ 22
E perimental Stuff .................................................................. 26
by Eric Weber
Thingiverse URL: http://www.thingiverse.com/thing:114784
Revision 4
13/7/ 013

B O T M O B I L E
1
Tools & Part List
ollowing tools and components are required to fully assemble the Makerbot
Botmobile 2013. I ha e indicated the components which I ha e personally
tested with this design. Although I can’t guarantee it the other ariants listed
should work based on their specifications. Please lea e a comment on the
Thingi erse model page if you successfully tested other ariants so I can add them to
the list below for the benefit of all.
Tools & Consumables
Following tools & consumables are required to finish the Botmobile
• Sharp hobby knife
• 3mm Drill
• 2.5mm Drill
• CA Glue
• Metric hex key/Allen keys of 2 and 2.5mm
• Double sided Tape
• Zip ties
• ABS/PLA suitable grease (e.g. Super Lube)
• 1-2x JST Female 2 pin connector
(source:http://www.hobbyking.com/hobbyking/store/__9631__JST_Fe
male_2_pin_connector_set_10pcs_set_.html )
• Screws:
• 1x M3x10 Cap Hexagon Socket Screw
• 4x M3x25 Cap Hexagon Socket Screw
• 1x M3x30 Cap Hexagon Socket Screw
• 2x M3x4 Button Hexagon Socket Screw (brushless ersion only)
• 1x M3x7 Button Hexagon Socket Screw
• 1x M3x15 Button Hexagon Socket Screw
Chapter
1
F

B O T M O B I L E
2
RC Components
Following is a list of suggested (and mostly tested) components which will work with
the Makerbot Botmobile 2013. Tested components are indicted with a tick.
RC Transmitter & Receiver
(cheap option in case you do not yet ha e a surface RC system)
• HobbyKing HK-GT2B 3CH 2.4GHz Transmitter and Recei er
w/Rechargeable Li-ion Battery
(source:http://www.hobbyking.com/hobbyking/store/__31671__HobbyKin
g_HK_GT2B_3CH_2_4GHz_Transmitter_and_Recei er_w_Rechargable_Li
_ion_Battery.html )
RC Receiver
(For those who already own a Transmitter)
 SR201 2Ch DSM Sport Surface Rx - Coated by Spektrum
(source:http://www.horizonhobby.com/products/sr201-2ch-dsm-sport-
surface-rx-coated-SPMSR201 or http://radiocontrol-sports.com/radio-
systems/i-recei er-surface/sr201-2-ch-dsm-sport-surface-rx-coated.html )
9gram Servo
 HXT900 9g / 1.6kg / .12sec Micro Ser o
(source:http://www.hobbyking.com/hobbyking/store/__662__HXT900_9g
_1_6kg_12sec_Micro_Ser o.html )
Option 1: Brushmotor
(Ensure that you print the parts optimized for the brushmotor configuration -
BuggyInterior Brush.stl & GearboxBrushmotor_supports.stl)
 Motor: GWS 280 Motor Set (GW/EDP-150)
(source: Ebay and arious other online shops – search for the item code
GW/EDP-150, example: http://shop.rotor.com.sg/show-
detail.asp?prodid={A78F0DCF-B85C-457E-86C0-
6CA1B81FA90D}&pn=1#.UdrWaPml4Z8 )
 ESC: HobbyKing X-Car 45A Brushed Car ESC
(source:http://www.hobbyking.com/hobbyking/store/__32025__HobbyKin
g_X_Car_45A_Brushed_Car_ESC.html )

B O T M O B I L E
3
Option 2: Brushlessmotor
(Ensure that you print the parts optimized for the brushlessmotor configuration -
BuggyInterior Brushless.stl & GearboxBrushlessmotor_supports.stl)
 Motor: S2445-3200 Brushless Inrunner (3200k ) (14T)
(source:http://www.hobbyking.com/hobbyking/store/__15185__S2445_320
0_Brushless_Inrunner_3200k _14T_.html )
 ESC: Turnigy TrackStar 18A 1/18th Scale Brushless Car ESC
(source:http://www.hobbyking.com/hobbyking/store/__14630__Turnigy_T
rackStar_18A_1_18th_Scale_Brushless_Car_ESC.html )
 Pinion ear: Pinion Gear 3mm/0.5M 10T (1pc)
(source:http://www.hobbyking.com/hobbyking/store/__11204__Pinion_Ge
ar_3mm_0_5M_10T_1pc_.html )
LiPo Battery
(A LiPo Battery Charger and Balancer is required to charge this type of battery. Do
NOT attempt to charge it with a normal charger as the battery will explode).
Packs with the following dimension will fit the car: 70 x 35 x 13mm
 Turnigy 1000mAh 2S 20C Lipo Pack
(source:http://www.hobbyking.com/hobbyking/store/uh_ iewItem.asp?idPr
oduct=9170 )
• reat Planes LiPo 2S 7.4V 1000mAh Novus 200 FP
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXBPAW&P=7 )
Ball Bearings
(2x standard Skateboard 608 type - 8x22x7 - ball bearings are required)
 2x Ball Bearing (22x7x8mm) - 1/5 4WD Big Monster
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXFX65&P=7 )
• 2x 608RS 8x22x7 Bearing
(source: http://www3.towerhobbies.com/cgi-
bin/wti0001p?&I=LXFX65&P=7 )

B O T M O B I L E
4
Tires
(The Botmobile requires 4 rubber tires for the printed wheels)
 2x Thunder Tiger Fire Blade Tire, 26mm (PD9158)
(source: http://www3.towerhobbies.com/cgi-
bin/WTI0001P?I=LXATAV&P=8 or http://www.amazon.com/Thunder-
Tiger-PD9158-Blade-Tires/dp/B003DKQRZQ/ref=cm_cr_pr_product_top
)
• 2x 1:10 Scale Rubber Touring Car Tires w/Tread 26mm - Medium
Compound (2pcs)
(source:http://www.hobbyking.com/hobbyking/store/uh_ iewItem.asp?idPr
oduct=23292 )
OPTIONAL
(Connectors you might require for your charging leads/ESC/Motor)
 JST Female 2 pin connect
(source:http://www.hobbyking.com/hobbyking/store/__9631__JST_Female
_2_pin_connector_set_10pcs_set_.html )
 JST Male 2 pin connector
(source:http://www.hobbyking.com/hobbyking/store/__9630__JST_Male_2
_pin_connector_set_10pcs_set_.html )

B O T M O B I L E
5
Printing the parts
hen I printed the 2 prototypes after modifying the Makerbot original plans
I used exclusi ely ABS material only. Although the Botmobile should print
fine in PLA, I can’t guarantee that the gears will last gi en the friction and
resulting heat generated.
The Botmobile 2013 comes in 2 ersions. The brush motor ersion for normal 280
size brush motors such as the suggested GWS motor and the brushless motor ariant
which will work with 280 size BL motors and controllers such as the HobbyKing types
in the source list. Please print the correct Buggy interior (to fit the controller switch)
and gear box motor mount (BL and brush motor ha e different mounting hole
positions and sizes) depending on the ariant you select.
Thingi erse download Link: http://www.thingi erse.com/thing:114784
Print Settings
The grouping into color 1 and 2 below is a suggestion. Mix and match as you like.
I printed all parts with 0.2mm layer height for the prototype.
Color Set 1
(Dri e train, steering and seats)
• Axle&Bearing_Clips.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
• AxleGear.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s
Chapter
2
W

B O T M O B I L E
6
• GearboxShell.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
• Gears.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s
• Steering.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
• Wheels.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
o Print 2x
Option 1:
• BuggyInterior Brush.stl (Brushmotor Option)
Print with:
o 10% infill
o 3 shells
o 80mm/s
• GearboxBrushmotor_supports.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
o Enable supports

B O T M O B I L E
7
Option 2:
• BuggyInterior Brushless.stl (Brushlessmotor Option)
Print with:
o 10% infill
o 3 shells
o 80mm/s
• GearboxBrushlessmotor_supports.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
o Enable supports
Color Set 2
(Body, Windshield and RX brackets)
• BuggyBack.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
• BuggyFront.stl
Print with:
o 10% infill
o 3 shells
o 80mm/s
• Add_RX_Brackets.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 80mm/s
• WindShield.stl
Print with:
o 100% infill
o no additional shells = 1 shell
o 40mm/s

B O T M O B I L E
8
Assembly
nce all parts are printed and all components are a ailable, we can put the
Botmobile 2013 Dune Buggy together and take it for a spin.
Follow the picture guide below and also consult the original Makerbot
Botmobile assembly instructions at:
http://www.makerbot.com/support/projects/botmobile/ for additional information
if required.
Steering assembly
Following parts are required to complete the steering assembly:
- All parts from the steering.stl file printed as per description in chapter 2
- 9gram ser o with straight ser o arm and smallest screw
Chapter
3
O

B O T M O B I L E
9
Attach the swing arms to the control arm
Attach the swing arms and control arm assembled in the pre ious step to the steering
base.
Attach the steering top mount/ser o holder to the assembly as shown abo e.

B O T M O B I L E
10
Press the ser o into the steering assembly from the bottom (picture abo e shows the
top iew) by first sliding the ser o mounting tabs on the cable side into the ser o
holder and then snapping in the opposite tabs into the mount. A bit of force might be
required. Use a hex key to push the tab down but be careful not to break them.
Center the ser o using the RC Radio. Install the steering arm by pressing the ser o arm
into the steering linkage (a bit of trimming might be required for a snug fit) and
afterwards install the steering arm on the ser o as shown abo e. Once secured with the
ser o screw, trim the excess ser o arm with a hobby knife.
Install the retainer clip as shown abo e

B O T M O B I L E
11
Gearbox & Rear Axle
Following parts are required to complete the steering assembly:
- All parts from the following stl files printed as per description in chapter 2
o Axle&Bearing_Clips.stl
o AxleGear.stl
o GearboxShell.stl
o Gears.stl
o GearboxBrushmotor_supports.stl
or
o GearboxBrushlessmotor_supports.stl
- Brush or brushless motor as per source list
- 2x 608 skateboard bearings (22x7x8mm)
- 1x M3x15 Button Hexagon Socket Screw
- 1x M3x10 Cap Hexagon Socket Screw
- 1x M3x30 Cap Hexagon Socket Screw
- Brushless only:
o Pinion gear as per source list / suggested GWS brush motor
comes with pinion gear pre-installed
o 2x M3x4 Button Hexagon Socket Screw / suggested GWS brush
motor comes with suitable mounting screws

B O T M O B I L E
12
Start by re-drilling the holes in the outer gearbox shell and spruce gear.
Drill the spruce gear hole to 3mm (it might be slightly smaller depending on your
printer settings). Test fit the M3x15 Button Hexagon Socket Screw and make sure the
gear can rotate freely on the screw.
Re-drill the spruce gear mounting hole (left hole in the gear shell as shown in the
picture abo e) with a 2.5mm drill and finally re-drill the right, deeper hole in the gear
box to 3mm.
Apply some grease on the M3x15 Button head screw and screw the spruce gear into
place as shown abo e. Tighten the screw but ensure the gear can spin freely.

B O T M O B I L E
13
Brushless ersion: before you install the motor in the motor mount, trial fit the pinion
gear and check whether the flat spot on the motor axle needs to be cut deeper in order
for the screw in the pinion gear to catch properly (was the case in my build).
Next install the motor into the motor mount as shown abo e (after remo ing the
supports from printing). Use the M3x4 Button Hexagon Socket Screws if you are
building the brushless ersion.
For the final assembly, prepare all remaining parts as shown abo e.
Re-drill the dri e gear to 3mm and ensure that it can spin freely on the M3x30 screw.

B O T M O B I L E
14
Insert the M3x30 Cap Hexagon Socket Screw into the gearbox shell from the outside.
Apply some grease to the screw and install the dri e gear as shown abo e.
Place the motor mount onto the outer gearbox shell as shown abo e (check the
position of the motor pinion gear and adjust its position on the motor axle if
necessary). And secure the 2 parts together with the pre ious installed M3x30 (tighten
the screw only till it comes out of the other side of the motor mount) in the middle and
the M3x10 Cap Hexagon Socket Screw at the outer end as shown abo e.
Install the other outer gearbox shell and completely tighten the M3x30 screw.
Carefully check that the gears can spin and adjust of necessary.

B O T M O B I L E
15
Once done, the gearbox assembly should look like the abo e picture.
For the final step we will combine the main dri e gear, axle, axle clips/ retainers and 2x
608 ball bearings with the gearbox assembled in the pre ious step.
First slide the ball bearings o er the axles and push the axles into the main dri e gear.
Ensure that both sides ha e an equal length. Some trimming might be required to get
the axles to fit properly. Ensure a snug fit and apply some CA glue if necessary to
secure the axles in the main dri e gear once the length is aligned properly.

B O T M O B I L E
16
Place the ball bearings into the gro es in the gearbox and snap the axle clips/retainers
in place.
The axle should now be firmly attached to the gearbox and the main dri e gear should
be in constant contact with the gearbox dri e gear.
Building the chassis of the Buggy
Prepare the 2 Body hal es, interior (brush or brushless ariant), 1x M3x7
Button Hexagon Socket Screw and 4x M3x25 Cap Hexagon Socket Screws.

B O T M O B I L E
17
Remo e the print supports from the front (RX compartment) and rear (LiPo
compartment on both sides). They should snap off easily.
Abo e picture shows the front and rear after remo al of the supports.
Re-drill the front hal e mounting holes with a 3mm drill. Do the same with the single
rear hal e interior mounting hole near the gearbox mounts.
Align front and rear hal es and secure them in place with the 2x M3x25 screws

B O T M O B I L E
18
Slide the interior into the body shell (from rear to front) and press it in place.
Secure the interior in place with the M3x7 screw
Align the steering assembly and route the ser o cable through the gap as shown abo e