by Dremel ®
Let's Get Started
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.
Start by drawing out your pattern onto your plywood material. You can follow our pattern & dimensions or measure to lifesize dimensions of the future owner of the robot rack! Our robot's dimensions are: • height 49" • head 8" x 7" • neck 5" x 7" • belt 15" x 3.5" • upper arm 8" x 3" • forearm 7" x 3" • hand 5" x 3" • base 14" x 12"
Clamp your plywood to your worktable and use your Saw-Max tool equipped with the SM500 blade to cult along the marked lines. You may find it easiest to divide your material in a few different manageable pieces before cutting out individual parts. If you want to make a rounded edge, you can make a quick angled cut with your Saw-Max tool and round them out with the Multi-Max. Or check out the Snake Puzzle project we featured this month for tips on using the Moto-Saw for detailed and curved cuts!
You'll notice that the abrasive Saw-Max cutting wheels leave behind a nice, smooth finish. However, if you want to sand the edges of your cuts, mount MM70W Sandpaper to your Multi-Max tool, set the tool to high and lightly smooth out any rough areas.
When you're ready, begin connecting your pieces together with 1-1/2" wood screws. At this step, start by joining the head to the body with the neck piece, drilling through the back.
To create a unique belt for your robot as we did, mark a line 1 inch from each side of the belt piece and cross marks evenly to create a pattern on which you'll drill your holes. Using your power drill, drill 1/2" holes at the cross marks & attach the belt to the body with screws through the back.
Next, cut your 2x4 material to the width of the legs at the bottom and screw to the back of the robot, flush with the bottom. If you've never cut a 2x4 with your Saw-Max tool before, you'll be surprised at how easily you can tackle this task. Measure and mark your line of cut on the 2x4. Place the guide near your measurement marks. Leave about a 1/8 inch between the guide and line to accommodate for the kerf of the wheel and its slight offset. Clamp the guide in place. Make your first pass, then flip the board over to complete the cut all the way through the 2x4 on your second pass.
Attach the 2x4 to the base by screwing up through the bottom of the 2x4. Next, attach the foot base sides by screwing through the bottom and into the 2x4 bracket from each side.
Finally, clamp the upper arms onto the shoulder with the arm behind the shoulder and drill a hole through both pieces. Join with a bolt and wing nut. Repeat the process with the forearm pieces, placing them on top of the upper arm. Repeat for the hands with the hands behind the forearms. Finger tighten wing nuts enough to hold arms and hands in desired position.