Build · Assembly

Assemble it like it has to come apart tonight.

Combat assembly has two jobs: survive the hits, and come apart fast for repairs. Both are decided by how you fasten plastic.

Assembly safety:eye protection when drilling or using power tools. Never assemble with the battery connected — remove all power during mechanical work. Never force parts; if something doesn’t fit, check alignment and tolerances.

The assembly sequence

In this order, so you never have to disassemble a finished section:

Step 1

Chassis preparation

Test-fit all chassis components before final assembly. Check clearances around motors, electronics, and moving parts.

Tip: Sand, file, or Dremel tight spots found during test assembly — far easier before parts are fastened. Then fix the issue in CAD for the final print.

Step 2

Motor installation

Drive motors should slide easily into their mounts. If using mounting screws, apply threadlocker so they don’t back out.

Tip: Press-fit rule of thumb: about 0.2 mm of tolerance.

Step 3

Electronics installation

With motors in, route motor wires and mount ESCs, receiver, and the rest with proper wire management.

Tip: Complete all wiring at this step — the prototype chassis is your wire-management guide; make final tolerance edits as you approach the final print.

Step 4

Wheel hubs & shaft collars

Slide shaft collars onto the wheel hubs, then install the assembly on the shafts. The long set screw interlocks hub and shaft so wheels can’t slip in a fight.

Tip: Put an access hole in the wheel so you can reach the set screw after the hub and collar are on the shaft. Threadlocker on set screws.

Step 5

Final chassis assembly

Install top plate(s) and any upright components to complete the structure.

Tip: With plastite screws, do not overtighten — they will strip the printed part.

Motor mounting & retention

Drive motors

Screw-mount through the gearbox — threadlocker on every screw
Printed braces that physically constrain the motor
Check the wheels sit parallel and nothing binds
Leave access for wiring and maintenance

Weapon motors (press-fit)

Hole 0.1–0.2 mm over motor diameter for a light press fit
Steady, controlled pressure: vise, arbor press, or clamp
About 6 mm of wall around the motor mount
Verify the shaft is perpendicular to the mounting surface

Wheel hubs & collars

D-shaft bore in the hub to match the motor’s D-shaft
Set screw tightens against the shaft flat
Threadlocker on set screws for high-load drive
Position the collar to compress against the flats

Fasteners for printed parts

Plastite screws (recommended):thread-forming screws that make strong threads in plastic without removing material. Common sizes for antweight work: M3 and #4, 3/8" long. Drill the pilot hole at the manufacturer’s specified size, and don’t overtighten.

Heat-set inserts beat screwing into bare plastic wherever a joint comes apart repeatedly — set them with a soldering-iron installation tip, keeping the insert square to the hole. Threadlocker goes on any metal-to-metal screw that vibration can reach (motor screws, set screws).

Before you test

All fasteners tight; threadlocker where specified
Wheels parallel, spinning free, no binding through full drive motion
Wiring secured away from moving parts; battery bay clean
Weapon lock installed

Next: testing →Back to printing