Start with the bottom base plate.
Insert the four 3.5” long ¼-20 bolts into the four offset holes on the base plate.
Add the 2” long nylon spacers and two split washers to each bolt. If the base plates are less than 3/16” thick, some extra washers may be needed, or shorter bolts should be used.
Next, set the base plate aside for a moment and attach the four stepper motors to the brackets using two M3 screws per motor.
Add a very small drop of super glue to the edge of the drive shaft on the motor and affix the 3D printed pulley to the motor. Push the pulley on the motor enough so that the edge of the shaft lines up with the edge of the pulley. When attaching, the small hole on the pulley should be towards the front, circled in green.
Repeat this step for all four motors.
Place the motor assembly on the base plate, align the bottom of the bracket with the inner holes on the base plate like the picture shown below.
In one of the inner holes, insert a 6-32 bolt and tighten it into place with a 6-32 lock nut.
Shift the motor down so the edge of the bracket lines up with the base plate. Add another 6-32 bolt and lock nut to the outside hole, on the opposite row of the first bolt to fix the motor in place.
Repeat this for all motors. Cut four 24” lengths of fishing wire and tie one to each pulley using the small hole on the lip of the pulley. When finished, the assembly should look like this, with a small bundle of fishing wire on each motor.
Add this new base to the bottom of the assembled robot and tighten the bolts with the ¼-20 nylon lock nuts. Feed the second stage fishing wire up through the first stage and through the middle disc. Have the wire rest freely here for now.
Next, use a hacksaw or bolt cutters to remove the loop at the end of the spring on the robot and the loop at the end of the spring for the modular portion. It is possible to not remove this loop and to simply hook the two springs together after removing the old disc and before attaching the modular spring link like the image shown below.
If the spring is chosen to be cut, it takes a decent amount of sawing the completely cut the loop off. If the loop is left there, it will take some twisting to get the modular link on.
Remove the top disc from the robot (circled in red) and replace it with the modular spring link disc (circled in green).
If the springs were looped together, push the modular spring link onto the top of the second spring and move the link down until half of it covers the bottom spring and the other half covers the second spring. To move the think, it may be necessary to twist it up and down to slowly move it into place. Another way to move the link is to twist the link in the same direction that the spring is coiled.
Line the top and bottom of the link with some hot glue to fix the spring in place.
Add a middle disc to the second stage spring and re-attach the structural disc removed from the first stage to the second stage.
Finally, run the second stage fishing wire through all discs and links on the robot and tie the wire to the top disc.
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