The Go Baby Go Build Manual The step-by-step guide to creating your own Go Baby Go Car 4488 Shockwave Robotics and Pacific University
Index 1. List of Mat erials 2. Mechanical Assembly a. Installing the Button - Page 2-7 b. Installing the Back Board - Page 8 c. Installing the Seat Belt - Page 9-11 3. Electrical Assembly a. Spade Connector Tutorial b. Remove Steering Wheel c. Disconnecting Steering d. Removing Dashboard i. Dashboard Removed e. Disconnecting Radio Toggle f. Radio Bypass g. Removing Power Switch i. Feeding Power Switch Through Dashboard ii. Cover Power Switch Hole h. Removing Shifter Handle i. Removing Shifter Switch i. Disconnecting Shifter Switch ii. Bypassing Shifter Switch iii. Reassembling Shifter j. Removing Gas Pedal i. Disconnecting Gas Pedal k. Power Switch i. Drilling Power Switch Hole ii. Inserting Power Switch into Hole iii. Reconnecting Power Switch l. Button Wiring i. Drill Button Wiring Hole ii. Running Button Wiring iii. Connect Button to Gas Pedal Wiring m. Reinstall Dashboard n. Reinstall Steering Wheel 1
Materials Tools Needed (1) Hot glue gun + sticks (1) Pair of scissors (1) Philips head screwdriver (1) box cutter (optional) (1) electric drill (1) ¼ inch (6.35mm) drill bit (1) ¾ inch (19mm) drill bit Needle nose pliers Terminal crimpers Flush cutters Screwdriver Drill Wire Cutters Raw Materials Needed (1) Piece of dense foam at least 60 cm by 30 cm in size Foam should be approximately 2.5 cm thick Zip ties (large and small) 25 cm of surgical tubing or elastic material Prefabricated Polycarbonate seat back board 3 m of flat nylon straps (for the seat belt) (3) Plastic buckles/clips sets (parachute buckles) (4) Female spade crimps (7) ½ inch to 1 inch (1.25 cm to 2.5 cm) long bolts (¼ - 20) (7) Thin washer to fit the bolts (7) Lock nuts to fit the bolts (1) Button Electrical tape 2
(2) Jumper wires Car 12V (dimensions?) Big red twist switch Mechanical Assembly Installing the Button 1. Drill one ¼ inch (6.35 mm) hole parallel to one of the pre-drilled holes on the button s backing. An imaginary line drawn between the parallel holes should be perpendicular to the cord attached to the button. 3
2. Cut an 25 cm length of surgical tubing (or a similar elastic material elasticity will affect necessary length). 3. Thread a zip tie through one of the parallel holes and engage it to form a large, loose, loop. 4. Pull the surgical tubing through the zip tie and stretch it until it is taut, there should be about 2.5 cm of tubing sticking out of the outer edge of the loop, then pull the zip tie tight. 5. Clip any excess material using the wire cutters. 4
6. Place the button on the sheet of high density foam, the red part of the button facing up, and trace it. 7. Remove the button and draw a 5 cm wide channel down the center. 8. Extend this channel past the edge of the drawn circle by 30 cm. 9. Cut out the circle and channel. 10.Use a hot glue gun to attach the two semicircles to the back of your button. 11.There should be a 5 cm channel in between them that is perpendicular to the imaginary line between your surgical tubing attachment points. 12.After securing the first semicircle, use the cutout foam channel to help in positioning the second semicircle. 5
13.Take the foam channel you cut and attach it in the center of the seat back board. It should be flush with the top of the back, if there is un-occupied space at the bottom this is fine. 6
14.Position the button on the pre-cut back board as if it were about to be used, then pull your surgical tubing (or other elastic material) around until it holds the weight of the button to the headboard. Make a line where the excess material begins, make another line offset one inch (2.5 cm) into the excess material. Repeat the securing part of step 2 on the other side of the button, attach the zip tie at the first line, cut at the second. 7
Installing the Back Board 1. Remove the seat from the car according to the car manual. 2. Clamp the pre-cut back board to the center of the back of the car s seat. Ensure that the back board is flush with the bottom edge of the seat. Make it as perpendicular as possible. 3. Drill through the holes already in the polycarb with a ¼ in (6.35mm) bit. Important: Only drill through one layer of the plastic seat, not both! 4. Attach the seat back board to the seat using ¼ in (6.35 mm) bolts and lock nuts. 8
9 Installing the Seat Belt 1. Drill two ¼in (6.35mm) holes in the back of the car. They should be in line with the holes on the seat and in between the taillights and roughly 5 cm apart.
10 2. Bolt two loops of nylon strapping about 20 cm long attached to seat clips in the new holes. (see picture) a. Use a clamp to hold the strapping, then drill through to create the hole (optional, if there are two people on can hold the strapping in place while the other drills). b. In order to prevent fraying, melt the cut edges of the strapping. This can be done using a lighter or similar heating device. 3. Drill a hole through the center of the bottom lip of the seat 4. Attach another 20 cm length of strapping with a clip to that hole 5. Clip the strapping to the front clip 6. Bring the nylon strapping forward
7. Thread them through the cloth harness, through the slots in the back board, and to the outside of the car then clip it to the two original clips you placed. (See drawings) 11
Electrical Assembly 12
13 Spade connector removal tutorial 1. Locate bump where the connector begins to narrow 2. Pinch bump with pliers 3. Pull
14 Remove Steering Wheel NEED PICTURE Disconnecting Steering NEED PICTURE
15 Removing The Dashboard 1. Using the screwdriver, remove the screws marked by the green circles. Note that two of the screw are behind stickers.
16 Dashboard Removed This is what the wires going to the dashboard should look like.
17 Disconnecting Radio Toggle 1. Disconnect the wires going to the dashboard from the rest of the car. Disconnected Radio Toggle 1. Disconnect all wires going to the LARGER switch, use the method described during the Spade connector removal tutorial
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19 Radio Toggle Bypass 1. Take one of the jumper wires and the white wire and red wires you just disconnected from the radio toggle. 2. Connect one end to the white wire and the other end to the red wires 3. Wrap both connections in electrical tape
20 Removing Power Switch 1. Push the power switch (smaller black one on the dashboard) through its hole in the dashboard.
21 Feeding Power Switch Through Dashboard 1. Pull the wires connected to the power switch through the hole Cover Power Switch Hole NEED PICTURE
22 Drill Power Switch Hole 1. Mark on the hood approximately 3 cm to the right of the center of the hood and above the center sticker. 2. Drill a hole at that mark using the ¾ (19 mm) drill bit
23 Insert Power Switch Into Hole 1. Take the power switch and all of the wire attached to it. Feed the wires through the hole you just drilled and then push the switch into the hole, it should snap into place. Picture of full inserted switch
24 Reconnect Power Switch 1. Reconnect the wires attached to the power switch to the connector you disconnected it from earlier
25 Reattach Dashboard 1. Place the dashboard back in its original position. Using a screwdriver, screw the 5 screws that hold it on back in.
26 Reattach Steering Wheel Picture needed Removing Shifter Handle 1. Using a screwdriver, remove the one screw holding the stick in place. Bend the handle forward then pull it out.
27 Removing Shifter Switch 1. Flip the car over and push the switch you just uncovered through the hole.
Disconnecting Shifter Switch 1. Remove the yellow wire from the switch, use the method described during the Spade connector removal tutorial 2. Remove the orange wire from the switch, use the method described during the Spade connector removal tutorial 28
Bypassing Shifter Switch 1. Take the jumper wire 2. Connect one end to the yellow wire 3. Connect the other to the orange wire 4. Tape the connections 29
Reassembling Shifter 1. Insert the switch back into the hole it was removed from 2. Slide the shifter stick back into place 3. Screw it back in 30
Removing Gas Pedal 1. Flip the car upside down, use the screwdriver to push the grey tab in, releasing the gas pedal. 31
Disconnecting Gas Pedal Switch 1. Remove the two spade connectors from the gas pedal switch using the method described during the Spade connector removal tutorial 32
Push Out The Gas Pedal Wires 1. Push both wires that go to the gas pedal through the hole they run through 33
Reattach the gas pedal 1. Push the gas pedal back in, the tab should lock into place. 34
Drill Button Wiring Hole 1. Make a mark on the shifter stick side of the car. Place the mark in line with the shifter stick and between the stickers. 2. Drill a hole at the mark using a ¼ (6.35 mm) drill bit. Push Button Wire Through Hole 1. Take the button and push both of its wires through the whole you just drilled. 35
Run The Button Wires to The Gas Pedal Wires 1. Flip the car over and pull the wires through until you have enough length to reach the wires which you disconnected from the gas pedal earlier. 36
Connect Button To Gas Pedal Wires 1. Connect the wires from the button to the wires from the gas pedal (it does not matter which two are connected to each other) then wrap the connection in electrical tape. 37
Manage Button Wire 1. Fold the gas pedal wire to button connection over onto the wires that run along the bottom of the car. 2. Wrap a Zip tie around the connectors and the wires that run along the bottom of the car. 3. Pull the zip tie tight and cut the tail off with flush cutters 38
4. Run the button wire back along the bottom to the middle of the car 5. At this point, wrap a zip tie around the button wire and the bundle of wires running along the bottom of the car. 6. Pull the zip tie tight and cut the tail off with flush cutters 39
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