Start by cutting out the body template using poster board. This is in the shape of a T. The motor mounts, which are the side of the T, are squares. The size of the square is the diameter of the motors. For our Herbie, that size was 3 cm by 3 cm. The middle of the T is a rectangle. In our Herbie, this was 5 cm by 10 cm.
Once you have the poster board template cut out, compare it to the motors and ensure that you are satisfied with it. If you are, then use the template to cut the body out of your Sintra.
Clamp on to the line where the rectangle meets the motor mounts. I used a pair of vice grips. These worked, however left grooves from the teeth. Any kind of metal clamp would work as the goal is to hold the Sintra and sink the heat.
Having clamped the rectangle, heat the motor mounts until the Sintra becomes pliable. Once it is, bend it down at a sharp angle, and then bend the Sintra around the motor. Before the Sintra has time to cool, secure the motor to it with pipe clamps.
Drill holes in the back of the base for the battery holders, a single hole in the middle to feed the wires thru and hold the circuit in place. Drill two 7/64" holes holes in front to feed the cable ties thru and secure the front wheel.
Free-form the circuit.
Finish up the robot.
Yes, I know this is very short on details. Please email me if you are building a Herbie such as this one, and have any questions. You can find my email address on the Home > Roboticists page.
