[Slumping Mechanism][Light Rods & Brain][Crown][Arms][Collar][Claws & Wrists][Tread Section][Tread Motors][Side Panels][Legs][Waist Plate][Microphone][Torso][Neon Back Plate] [Neon] [Power Pack][Vents][Radar Section][Ears and Spinners][Chest Lights][Wheels][Hinges][Knee Plates][Leg Pins] [Software][Programming Bay][Electricals1] [Electricals 2] [Radio Control] [Power Down Voice Synth] [Paints &codes ][For Sale or Exchange] [Downloads] [Modify Your a CD Rom drive for B9][Freight Chart]
Double Click on the Pictures to Get a Larger View (most pics)
|Slumping Mechanism||Looking for something to make your B9 Slump... here's a solution. The base of electric seats used in most modern cars. The 2 opposed motors are acme screw drives, driven from a right angle gear box. They are designed to work independently. For our purposed we can wire them in parallel but with the polarity reversed, so that when one motor winds out the other winds in, giving a seesaw action.|
|Light Rods & Brain||
Well after careful
consideration, I have opted to try something a little different to create
the light rods. Using 6.35mm stock aluminium tube (1/4 inch for the
US people) and 10mm Diam Tube for the light housing, I had the material
cut to size (although they were not accurate). To mount the light housing
on the stock I used some rubber vac hose from a local auto parts dealer.
Using 5 mm of hose on the stock this creates a spacer and cleave for the
light housing. Using superglue gel to harden the rubber I pushed the
housing over the rubber then slipped the stock into the centre. Takes a
bit of doing as aluminium doesn't really grip with superglue. Once the
stock is centred in the light housing, I let it stand for a few hours.
Then Using bondo made a tapered section on the rear of the housing (makes
it look nice and neat) The pictures here show various stages of
construction. Once they have been assembled, I will get them painted in a
plasticised paint so that the bondo does not separate from the aluminium.
HINT: Sand the aluminium prior to applying the bondo, this will give the bondo something to grip on to.
All the painting will be done by an Auto Refinisher who happens to be a friend of mine. The Torso when it is finished will be done in a 2 pac air dried.
Here's the brain cup with the light rods attached.. Looks good
hey! I am still deciding whether or not to use 12 light rods or just
seven. Some plans show 12 others show 7. lol.. Just another reason to
watch a few more episodes of Lost In Space.Well we are getting there, this
pic shows the brain partially assembled and lit up... :)
I decided to rewire
the brain section. I wasn't happy with the way in which the lights where
fixed or the fact I had one power line. So now there are 4 circuits in the
brain section and brass tubing acting as both a secondary earth and a more
robust mounting arrangement. The brass tube runs across the lamp fittings.
All the wiring is held in place by stick down cable tie mounts and cable
ties. The Cables are terminated on 2 sections of 3 way tag strip. The
corresponding wiring harness will be terminated to a 12way molex
connector. The Crown now has a brass sleave bearing and centre drive (
found a model boat propeller shaft for that. I am still searching for some
lower wattage bulbs for the light rods. The power consumption of the light
rods is 35watts.. Way too high. Ok here's the trick... I went for
Automotive flasher cans to flash the lights... and I hate to say it... old
technology works....If you watch a vide of LIS you will see that the
lights fade and NOT go out... It is the differential between the faded
voltage and the full voltage that gives the appearance that the lights
were off.... They look brilliant... if i get the time i will record a AVI
file so u can see what I mean... Also, sorry plain globes looked a little
boring.. so I painted them yellow... and they actually glow orange... Nice
look... The next trick is to motorize the crown... I am taking a very
simple approach to that, single 12v motor attached to the support for the
brain with a belt drive to a pulley mounted in the shaft. Once i have
finished I have finished ironing out the details I will post a pic for
you... Oh for those wondering how I mounted the brain section.. It
is VERY simple.. a Pvc flange with 50mm bore, it came as about 20cm in
diameter.. I cutting down with the dremel, sanded it smooth. Using the
brain cup as a template.. drilled the 4 mounting holes. I tapped the
mounting holes with a 4mm thread and used 316 stainless steel hex nuts and
washers. The Flange was painted chrome. The rubber boot is fixed to the
out side of the flange using Polyurethane. (Stikafelx) This covers the
50mm bore PVC pipe section which will drop down thru the radar assembly.
(all of this painted chrome too .. I know it wont be seen...) Woohoo
managed to obtain a one piece bubble!! Hold on to ya seats... Next pic
will show the brain encapsulated!!!
|Like everyone else building a B9, my robot is a constantly
evolving piece of work. I searched the net and saw a crown I liked better
than the aluminium one I have now. After looking at the plans again and
again..and again, I decided to get a stainless steel crown cut (laser
cut). I will have pics available when the parts arrive.
OK I cant help my self, I had a stainless steel crown made (or should I say cut). After 5 hours of polishing, and an hour of drilling and 30 minutes of riveting .. Its done and here is what it looks like.
Due to my lack of both
tools and skills, I chose to get a mould made for the arms. The plans for
the plug used in the mould are below. Using the method described at the
B9BuildersClub, for making the bubble lifter, the finished product should
be quite nice. Pictures to follow.
The plug is being made from a single piece of wood and finished ready to be handed over to the fibre glassing company, who have been more than helpful with regards to the process of actually casting the Arms.
Stop press * New
company is making the castings for me.. will let you know how and what
when I get the details.
If your are having trouble getting a suitable material for the arms... Try Couplings, In Malaga, WA . email me for the address/phone number.
|Collar||Whoohoo the collar! Doesn't it look pretty..Cant wait to get the radar section on top of it!|
|Claws and Wrists||
There they are, claws and
wrists. Made of cast resin they are ok. I am getting a cast made so i can
redo them how I want them, but these will do to get the Robot looking like
it should. They also will be repainted.. The paint job is a bit off
colour. I have repainted one of the wrist, and i think the colour is much
Motorising the claws.. now there's a challenge. The only thing I could find that would work was a door locking solenoid for a car.. and in fact it worked quite nicely. The claws will stay in the close position or the open position depending on the polarity of the voltage sent to the motor. Depending on how your claws are setup, there shouldn't be too much trouble applying the idea I have used for the claws. This however was my initial effort at motorising he claws, before I started using the RC, now, I am using a servo to open and close the claws.
Hint: If you are using resin claws, do not supply the full 12Volts to the motor, use 6 volts. This will help stop the "SNAP" effect of the claws closing, and will prevent any damage to them.
Here's a pic of the solenoid motor, I think you will get the idea jut by seeing the motor, on how to set it all up. If you use the master motor in one claw, the slave can be wired directly to the master, otherwise you will need to wire them both back to what ever you use to fire them. I picked mine up from an auto electrician, he had heaps of them laying around and was glad to get rid of a few. I think you could use them for the soil Sampler door too!
|I have moulds done for claws and wrists - check out parts for sale & exchange.|
So much wood! Well here
is what the wood looks like cut.. Takes a fair bit to make the legs!
Go ArfA... Sorry, I am not that good with a saw..lol
Ok this is how i made
my legs. Damn stapler was useless!!! so.. I used industrial grade carpet
cement. An using the steps below, I managed to get the leg pieces to look
fine. Here's the tip, brush the cement onto the wood piece first. Then
while that is starting "go off" cut the foam tubing. By the time u have
finished cutting the tubing, the cement will have started to go tacky. Now
brush some more glue into the foam tubing. Let that stand for a little
while (not long a minute or 2). Now simply roll the leg piece into the
tubing, using a firm but even pressure. Trim off the excess tubing and
using super glue, join the ends. Be warned foam tubing gives off fumes and
gets hot when super glue is applied. Now just go round the edge and pull
the foam tight. Because the cement is tacky, there will be very little
movement after you apply pressure to the surfaces.. and hey presto.. one
piece finished. To aid in the setting process, I stacked the pieces on top
of each other using some spare wood to add weight.
Here's the waist plate, I haven's finished sanding or
polishing it yet, but it is still pretty impressive. You can also see the
knee plates and hinges. This is just a stack up, as you can see, nothing
is really painted yet.
Originally I was going to use 2 windscreen wiper
motors, and gear them down so as to provide the torque to move this beast,
however, the cost of buying or building a gear box to suit was ridiculous,
so instead, I started searching for an alternate solution. What is found
was perfect, a second had wheel chair. I found just what I was looking for
at Ross's Salvage in Maylands. The motors work fine, they even have an
electric braking system... pretty cool, but I removed the electric brakes
so the power consumption is reduced. (The breaks needed power applied to
What do I see here ?
we are underway with the tread section. Made from steel, the tread section
features 5mm outer walls, 3mm inner walls and facings. The laser cut
patterns will be bent into shape to reduce the number of welds required.
Here is a Autocad rendering of one of the feet. Also, to make sure
everything is easy to setup correctly the engineering shop used a tab &
slot arrangement so the parts will be exactly where they need to be.:)
|Now .. to find a way to connect the knee bone to the thigh bone... Ahh here we go.. Leg pins! CNC Lathed aluminium pins.|
Now this was interesting, I received a set
of Styrene Side Panels, but, I thought they were a tad flimsy. I had in my
mind, "If some one kicks them, they will just break! So what to do? Ahh
Fibreglass. So off I went to the local hardware, and I got 2 bags of
Plaster of Paris, some plywood, and a length of pine. I made a frame to
hold the styrene in place, while the plaster of paris set.. and hey
presto, a mould for fibreglass side panels. (Don't ask me what people
thought when I told them I used cooking oil on the styrene..lol.. For
those who need to know, it was to stop the plaster bonding to the styrene.
Well looky here. What is that I see ???? Yes..It is the torso. Now I can't tell you where I got it from, but I can tell you.. If you live outside the USA, you better have a damn good cheque account balance. After nearly 1200$ Aus in freight alone it's here! Painted, cut and ready to be assembled! First cab of the rank, is fitting the Collar hooks. Made from 25 mm * 3mm aluminium stock bar. (see pic) they will act as a keyway lockdown for the collar. I will post a detailed diagram of the locks once I have completed them. Note, that these hooks will have to have measurements adjusted to suit YOUR torso and Collar.
To the gentleman who supplied my torso, thanks for persevering. Freighting was done by ABX Logistics (a world wide freight company). They were most competitive and offered the best advice on how to handle the shipment. http://abxlogistics.com Thanks Wayne! couldn't have done it with out your help. As for the other freight / intergrators get a grip people, 2500$ to ship it from the USA to Aus.. Cheaper for me to take a holiday!!
I have had a mould taken from t he torso (with the minor imperfections fixed up) so next trick will be getting another torso made up. See below if you require a torso.
Well.. umm... there are 2 pics of the neon, it was made in 2 pieces. Just
a tip, it's probably better if its a bit larger than a bit small... I
broke the main neon section as I was removing it from the back panel. New
main section should be ready in a couple of days. You will notice the
blacked out areas on the extreme edges of the neon. People ask why...
Simply, this area will not be exposed and by blacking it out no reflection
or stray glow can be introduced to the main neon area.
|Neon Back Plate (1)|
This would have to be the hardest part of the robot to get... Seems to be a mystery..I would have preferred a vac formed back plate.. and eventually I will make one, but for now, I have used 0.10 inch styrene and heat bent it into shape. Using a special styrene solvent (not a modelling glue) I have been able to make it with out much mess. Unlike most back plates, I decided to mount 2 speakers behind it, this is where the voice of the robot will come from. (Sounded logical to me). Using the dremel and a milling bit, I literally carved the holes out. They are not pretty, but the whole back plate will be covered with speaker cloth (matt black cloth) so I think it will look ok when its done. To mount the speakers, I glued some excess styrene blocks around the speakers and made a lip to hold one side in place. Between the 2 speakers i have a bolt that will have a plate that slides over the other side of the speakers, thus making it easy to replace them if need be. I am sure you will get the idea from the pics.
|Neon Back Plate (2)|
Not being happy with the back plate I made,
I decided to order a back plate from the B9 Club Store. The CR back plate
arrived airmail 3 weeks after it was ordered.. Pony Express Mail.. but
anyways, they arrived (yes 2 of them). Being nice and solid they seem to
be exactly what I needed. There is however, a hell of a lot of surplus
material to be cut away. I thought i was seeing things.. they were so damn
huge. I went ahead and cut one down, and kept the second one as a back up.
The results of the first cut are seen in the picture as the darker of the
2 neon back plates. This was cut down to the same shape as Dewey's back
plate. Yet more interesting things loomed! The CR Back plate was designed
to not only fit the mouth piece, but also shield all the way to above the
arm sockets! No that was a great Idea, I am glad I ordered 2. The second
of the 2 neon back plates (with extensions to the arms sockets has been
trimmed, but you will have to wait for that picture as the back plate is
at NELC where there are preparing it for the neon. (Some things have to be
done to the letter of the law), gluing the neon to the body of the robot
is against safety standards in Australia, also fixing it direct to the
back plate (Flush) would also be illegal. So I have to reach a compromise
on installation... and NELC were the best ones to do it!
The picture to the left shows a trimmed version (black) and the untouched version (white).
power pack is the most interesting part to work with. Using diagrams found
on the net, I created an etch pattern and etched a circuit board for the
power pack. Next finding the parts... Unfortunately, some of the parts are
no longer available and only current parts were used. I did destroy an old
power supply to get most of the resistors and one of the capacitors. The
"knobs" are in fact aluminium push buttons. The transistors are
2n3848's they were the only ones I could find that had the same casing as
the original. The frame is a resin frame as is the connector. The power
pack isn't accurate to the n'th degree and also is only single sided. One
of the 3.5mm phono plugs acts as a switch for the microprocessor to detect
a power down. Although not perfect it certainly looks the part.
Ahh the microphone. Now this one you will
get a giggle out of. It consists of an old cigarette lighter. Yes I did
say cigarette Lighter. My sister got me a novelty cigarette lighter years
ago... and guess what it was..? It was a microphone, albeit a small one.
I like the taper on the handle, so , I removed the internals and drilled
it out. However the actual mouth piece was too small and needed too much
work. Using a belt sander, I sanded the "knob" section off. I then
went looking for something that would give it the right shape.OH NO.. My
drill press had a knob that was perfect! Stuff the drill press.. So off
came the knob. After grinding and sanding and gouging, I had a shape that
looked much better for the microphone. Using "Super Glue" I glued it to
the handle piece. Added some car body filler and hey presto.. more sanding
required..and it was too light, so I used some brass tube and flattened on
end, I glued that inside, and filled the handle with body filler After a
little paint, it came up fine.. The brass tube will be "tied" to a
janitors key ring wire (the retractable type).
Superline Plastics are doing the job, they
sent the plans off to get the plastics laser cut! Cant' wait to see the
result! Superline Plastics are in Perth 08 9353 3477. I chose Superline to
do the job because they LISTENED to me.. If you need anything done in
plastics.. give them a call!
Well I am impressed! This is the parts for the radar assembly stacked (not glued yet) that is why there is a plexiglass pipe running though the centre (to align the pieces). These pictures show the pieces as they where cut. (you may notice the top and bottom discs of the lower radar assembly have notches.. The laser cutting company made a mistake!, but thanks to Superline's eye for detail i was notified about it and asked to go out and check it). The final radar assembly will be ready for pick up tomorrow. Craig (the guy making sure everything is right) was so helpful, Allan Dodd's well he didn't laugh at me and the rest of the staff were so helpful. I really cant tell you how happy I am with the service.
All I can say it.. If you need something done in plastics in WA see Superline, their factory is impressive and while I was there I saw some other things they were working on.. talk about blow me away.
Neck support - for
those of you who are interested, I used a rather unusual arrangement for
my neck support. If you click on the diagram, you will see how I did it.
Rather straight forward and it allows me to put a spring a round the whole
assembly (making it easier to create the bubble lift assembly) Oh no! I
started on the Radar spin mechanism... Will I ever stop? (I doubt it). I
have used a rear window wiper motor (from a Toyota , don't ask me what
model all I know is the smash repairer was going to throw it out). I cut
the mounting bracket down using the trusty dremel (I know why people rave
about them now) and carefully made a chassis for the motor to sit it in
out of acrylic. To grip the radar I used a wheel from a petrol powered
model car, bought from a local modelling shop. To make the wheel fit, I
had to carefully drill out the centre (too big and I would have had to
make some sort of wheel clamp), and using the 8mm nut on the wiper shaft,
i bolted the wheel down tight. The Neck assembly is clamped underneath the
collar, by both the wheel on the wiper motor and a second wheel (directly
opposite the wiper wheel). In total, there is about 45 degrees of movement
(left to right) which is enough to try the idea out, by pulsing the motor
left to right or right to left, the centre position can be located. (using
the software and relay board).
|Ears and Spinners||
The ears are made from cast aluminium, I
haven't attached the spinners as I am unsure at present wether or
not I will try to motorise them. Another job for the painter.. I am going
to keep him busy! A damn..i couldn't help myself. I painted the the
spinners. I also found motors for them.. but at $800 per spinner.. I don't
think so. One power ball....
Well thanks to Kirby, I have another option, and for now, I will be using it. A simple way of making the Spinners spin.
Ahhh finally, wheels for the B9. Made
from Teflon and machined by hand on a lathe (of course) all 32 wheels!!!
But they don't look too damn bad. The wheels will spin freely on the
Stainless steel axels in the tread section. Why stainless steel axels?
Well that's quite simple, SS is strong, and.. I wont have to worry about
corrosion. I wasn't going to have the wheels touch the ground, but they
are so solid, I don't think they will be damaged.
To the left you can see
the plans for the hinges I will be using. Made out of 3 mm steel, these
hinges will be welded to the knee plates. The knee plates are being made
as per the original (i.e. like upturned pans). The top part of the hinge
will be welded underneath the top knee plate, while the bottom part of the
hinge will be flush welded. I am not sure about the rivets though, I
may just use round head pins with split pins. That way the section can be
pulled apart if need be. (please note the plans are NOT to scale) .. I
ended up using stainless steel button head bolts. They looked fine.
|Knee Plates||For the knee plate I am using 3mm Steel Plate (laser cut) and folded down to give the 1/2" lip on the face of the plates. The top plates will have the top half of the hinge welded to the underneath (using the weld tab), while the bottom plates will have the bottom half of the hinge welded either to the surface, or, the hinge will pass through the bottom pate and be welded from bellow (the later option will look much neater). The hinges will be welded about 5mm in from the edge of the knee plates.|
Well ain't this fun, I
spend 4 days hunting around Australia for the lights ..
arrrrrrrrrgggggggggg, finally I have given up. The lights are coming form
the USA. Lots of spare lenses (just in case)..and the large Chest lights..
well I got the housings and the bezels the actual centres are going to
have to be remade so that they are the right height. Oh the Pain..The
The Square lights coming from the USA with the claws ect will be panel mounted on a stainless steel plate (currently under construction - See Pic). It has been drilled , but the holes need to be bigger and the front side needs to be sanded and polished a little more to remove some burrs (dam dremel tool slipped while i was removing a rough edge.) Notice i intent to mount thru the panel and not cut the square wholes. I really feel that it is un-needed.
Ok, I found some illuminated switches... Looks ok.. not great though. I think i will go with these for now, and eventually cover them with a new bezel and Plexiglass annunciators..
My electrical system is being driven from a single
source 13.8Volt DC power supply. The reason being, eventually the robot
will not require an ac source unless recharging. Power system is divided
into three sub systems.
2: Motor - The motor circuits are all 12 volt dc, with the motor relay board controlling which motors do what.
3: Sound - The sound system runs from 12 Volts DC (however the 5 volt regulator circuit supplies the 5 volts dc required for the cd rom drive)
All of the above is controlled remotely via a UHF remote control.
The motor relays are controlled by a laptop PC and the software bellow.
|Power Down Voice Synth|
In the series, when ever the power pack was removed, the B9 made and "aaaaaaaaaaaaaaaaaaaaahhhhhhhhh" sound. The Voice module I decided to use, records up to 30 seconds of sound with pretty good clarity. SO, after building the unit (it came it kit form) I recorded from a video tape, the sound of the robot going "ahhhhhhhhhhhhhh". Using a one shot delay timer connected to one of the jacks on the power pack, when ever the power pack it removed, the delay time fires the relay, long enough for the voice module to say "ahhhhhhhhhhhhhh" . Then, the whole robot powers off. Pretty simple actually. The switch on the voice module for playback only needs to be driven to ground to fire the sound, luckily enough that's exactly how I am using the Delay timer, it will also switch the light controller to power down mode. The voice module was about 34$ Aus, and is available from JayCar Electronics.
I got this Futaba 7
Chan Transmitter of Ebay, I think 7 channels should be enough..lol
Stanbridges hobby shop and Perth R/C for their ideas and help with
configuring the remote control side of things.
Having to put motors in
the robot would be pretty pointless if there was no way of controlling
them. I have been working on this program that allows the robot to walk
talk and do things either via tethered control to a notebook or by running
a predetermined script. This software talks through the parallel port to
an 8 Bit I/O decoder - relay interface card.
When it is finished I will offer to B9 Club members free of charge.
The right picture shows the interface board, and yes it works. This will switch the High Current Relays. The onboard relays are low current and considering the load from the tread motors, I think its wise to use these ones to drive high power relays. Also... I can use more than one board in the robot. These interface cards are addressable.. Not too shabby!!
I added a styrene cradle for the Relay board so I had some place to route cables neatly, also the two fuse boxes I ordered arrived. I am using standard 12 volt Automotive blade fuses. One of the fuses boxes will do power distribution for the lighting, the other will do the motors and associated motor circuits.
This was sent from the
USA, it had one error in it. There was an extra hole cut into the right
hand side of the panel. Easy fixed though, a little styrene, superglue and
body filler had that sorted. Same as all the other builders, I used
standard switches. To the left is a pic of the bay as I received it (I had
already tried to polish it by the time this picture was taken), below is a
pic prior to adding the decals and potentiometer (which will fill the
final hole). I used a semi gloss silver paint (modelling paint) to give it
the silver look, as the original finish was pretty ugly. You be the judge.
I decided to use the top of the tape bay to mount two of the three control
boards. The bottom control board is TOMW's light controller. The second
board (not shown yet) is a AVR Maxi with the ATMEL chip on it, that board
will monitor the position of the torso etc, it will also monitor the power
pack and if its pulled it will trigger a sound file and TOMs controller so
both go into shutdown mode. Cool hey. The Aluminium grate on the back of
the tape bay is to diffuse any light from the internals of the Robot. TO
mount the board on top of the tape bay, I used Double sided tape, and made
a base of Acrylic with 4 standoffs. Tom's controller is held in styrene
if you have any comments or suggestions regarding this page.. please email me at email@example.com
|Special Thanks to Trent Miles, Brian Wallace and the members of the B9 Club for their continued help in completing this project. Thankyou to Irwin Allen for sending me into the future when I was a kid. (did I say was???)|
Due to Australia's use of the metric system, I am unable to find a source for the acrylic in anything other than metric and this would throw the dimensions off too far.
DOWNLOADS (Removed due to expense of getting the plans done - if you are interested email me and I will give you the cost of the files. They are NOT expensive, but I do have to recover some of the costs of getting the plans drawn up. Trades will be accepted.
|ITEM||NOTES - CAD designs are professionally created using AUTOCAD2000 files are available in R14 and AutoCad2000. DXF files upon request. These files may be used for getting items laser cut. All plans are in metric and imperial (you select which measurement layer you require)|
|Complete CAD drawings of the Torso||Complete 3D Cad drawings of the Torso Section|
|Knee Plate Upper||Cad drawings of the upper knee plate (ready for laser cutting)|
|Knee Plate Lower||Cad drawings of the lower knee plate (ready for laser cutting)|
|Knee Hinge Upper||Cad drawings of the knee hinge upper (ready for laser cutting)|
|Knee Hinge Lower||Cad drawings of the knee hinge lower (ready for laser cutting)|
|Chest Bezel||Cad Drawing of the chest Bezel (ready for laser cutting)|
|Waist Plate||Cad Drawing of the waist plate (CNC milling or laser cutting)|
|Torso Construction Templates||A complete list of individual pieces required to scratch build a torso. (due soon)|
|Brain Section||Cad Drawings of the brain including hieroglyphic panels (ready for laser cutting) (due soon)|
|Crown||Cad Drawings for Crown base and fins (ready for laser cutting)|
|Tread Section||Cad Drawings for my steel tread section (ready for laser cutting)|
Need parts ? Check these out! Coming soon - All rubber
leg Upper and lower, Fibre Glass leg upper and lower.
I do not keep an inventory of parts, if you need something just let me know and I will get it sorted out for you. Also, being a fellow builder, the only charges added to the cost is effectively for petrol. There is no profit margin in these items. My Parts Page