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The HMC Heavy Metal Chassis Construction Guide
The Heavy Metal Chassis is constructed using two identical drive modules. The drive modules are constructed using 4 mechanical sub-assemblies. The drive modules are easily integrated into a single chassis using two cover plates.

Drive Module 2 1. Bulkhead Pair 2

3. Driven Wheel Assembly 2 Cover Plates(2) 2. Drive Wheel Assembly 1

2. DriveWheel Assembly 2

Drive Module 1 4. Motor and Sprocket Assemblies (2) 1. Bulkhead Pair 1

3. Driven Wheel Assembly 1 1. Bulkhead Sets (2 required)
There are four (4) bulkheads paired in two (2) sets. 2 students working together can construct all four bulkheads (both sets) in about 10 - 15 minutes. 2. Drive Wheel Assembly (2 required) There are two (2) drive wheel assemblies. 2 students workingtogether can construct both assemblies in about 10 - 15 minutes. 3. Driven Wheel Assembly There are two (2) driven wheel assemblies. 2 students working together can construct both assemblies in about 10 - 15 minutes. 4. Motor and Sprocket Assembly There are 2 motor and sprocket assemblies. 2 students working together can construct both assemblies in about 10 - 15 minutes.

Total chassisconstruction time for two students: 70 – 90 minutes.
105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com Copyright GEARS Educational Systems 2007

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Necessary Tools
Safety Glasses Phillips Head Screwdriver #1 pt. And #2 pt. Allen Wrench or Hex Key (sizes .050, 1/16, 5/64, 3/32, and 1/8) 3/8 “Wrench Wire Strippers and Crimpers Smooth File (Small) 3/16”round file (Similar to a chain saw file)

Materials
Structural/ Mechanical Qty. 2 Cover Plates 4 Bulkheads 4 3/8” dia x 4” keyed axles 4 3” Dia. Rubber Caster Wheel Assemblies With broached aluminum bushings 6 #25 Pitch, 20 Tooth Steel Sprockets With (2) #8-32 Set Screws 2 #25 Pitch, 16 Tooth Steel Sprockets With (2) #8-32 Set Screws 2 #25 Pitch, 100 Link Chain and Connecting Link assembly 2 #25Pitch, 42 Link Chain and Connecting Link assembly 8 3/8” ID Flanged Bearings 2 9.6 Volt x 19.7:1 Competition Gearhead Motors 2 3/32” x 3/32” x 2.3” Round End keyways 2 3/32” x 3/32” x 1.75” Round End keyways Hardware Qty. 4 #10-24 x 1/8” cup point set screws 8 3/8” (Nominal) “E” Retaining Clips 18-20 3/8” ID x 5/8” OD x 0.125” Nylon Spacer Washers 50 #10-32 x 3/8” Machine Screws 40 #10 LockWashers 4 #10 Flat Washers 18 #10 Nylon Locking Nuts

Electrical 2 ea. Wire Nuts (grey and blue) 4 ¼” Female Quick Disconnects 2 ¼” Male Quick Disconnects 2 0,201” Female Quick Disconnects 8” 16 ga Insulated Wire (blk and red) 1 Electronic Speed Controller 1 SPST Toggle Switch 1 Battery

Instructional Information
Power point Introducing the educational purpose and performance objectives of theheavy metal chassis project, as well as the components, sub-assemblies and construction steps involved in the project. Estimates of the average time required to construct the assemblies, modules and chassis integration once the students have been provided the parts and an overview of the performance objectives. Note: In order to maximize the educational benefit to the students and minimize the timeon task, it is advisable to introduce all the components and review this document with the students before beginning the assembly of the HMC.
105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com Copyright GEARS Educational Systems 2007

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Sub -Assembly 1 Bulkhead Sets (2 sets required)
( Average assembly time: 1 student about 10 - 15 minutes) Note:Since it is necessary to assemble 2 identical modules it might be helpful to assign two students to assemble this module and two other students to assemble the other identical module. Necessary Components and Tools Qty. 8 8 2 4 1 1 Description #10 Nylon Locking Nuts #10-32 x 3/8” Machine Screws Bulkhead Plates 3/8” ID Flanged Bearings 3/8” Combination Wrench (not shown) #2 Phillip Head...