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Step 1: Mount the correct gear to the servo.
Remove the current head from the servo, mount the new gear and washer to the servo and reuse the old screw.
Original photos (very large): 1A, 1B, 1C
Step 2: Prepare Part A's
Do this for both Part A's: mount the servo to the part using four 1/2" screws. Note the end the gear is on. Don't tighten the screws all the way, you'll need to align it later.
Original photos (very large): 2A, 2B, 2C, 2D, 2E
Step 3: Gear for Tilt
Take one large gear, one hub, and four 1/2" screws. Note which side the screw heads are on, it's important. Don't tighten the screws all the way.
Original photos (very large): 3A, 3B, 3C
Step 4: Prepare Part B
Take part B, one large gear, and one hub and mount them together using the 3/4" screws. Note the direction each piece points in, it matters. Don't tighten the screws all the way.
Original photos (very large): 4A, 4B, 4C
Step 5: Prepare one part C and F
Take a Part C and Part F and connect them using two 1" screws.
Original photos (very large): 5A, 5B, 5C, 5D
Step 6: Prepare Pan Assembly
Take the other Part C, the part completed above, and a completed Part A and mount them together. Note that the hole in Part F should line up with the hole in Part A.
Original photos (very large): 6A, 6B, 6C, 6D, 6E, 6F
Step 7: Prepare Part B assembly
Take Part B and attach the 3" axle to it. Tighten the set screw, then tighten the screws.
Original photos (very large): 7A, 7B, 7C, 7D
Step 8: Finish Upper Assembly
Attach the parts together.
Original photos (very large): 8A, 8B, 8C, 8D
Step 9: Complete Tilt Shaft
Take the 6" axle and the large gear assembly and attach them. Tighten the set screw, then tighten the screws.
Original photos (very large): 9A, 9B, 9C
Step 10: Make Gun Mount
Take Part D and attach it as shown. Do not tighten the screws all the way.
Original photos (very large): 10A, 10B, 10C
Step 11:
Attach the Pan to the Tilt. First adjust the servo position so that the gears mesh, then tighten down the servo screws. Next, the two brass gromets go in the holes. Note the order of Ring, Gromet, Plastic, Gromet, Plastic, Ring (top down). Adjust the rings until the gears line up, then tighten them down.
Original photos (very large): 11A, 11B, 11C, 11D, 11E, 11F, 11G
Step 12: Complete Tilt Assembly
First adjust the servo position so that the gears mesh, then tighten down the servo screws. Next, the two brass gromets go in the holes. Note the order of Gear, Gromet, Plastic, Part D, Ring, Gromet, Plastic, Ring. Adjust the rings until the gears line up, then tighten them down.
Original photos (very large): 12A, 12B, 12C, 12D, 12E, 12F, 12G, 12H
Step 13: Add the Electronics
Take the Pololu board and mount it with the extra-small screws and nuts. Then mount the PicoSwitch as shown using a zip tie.
Original photos (very large): 13A, 13B, 13C, 13D, 13E, 13F
Step 14: Mount the Safety Switch
Mount the switch as shown, note that the "down" end is the one with the tabs on it. Mount the gun to Part D and tighten the set screw, then the screws. Attach the wire length to one tab, and the wire from the gun to the other tab. The ends of each wire then screw into the PicoSwitch.
Original photos (very large): 14A, 14B, 14C, 14D, 14E, 14F, 14G, 14H, 14I
Step 15: Route Wires
Zip tie the wires along the edges so that they don't snag on anything. Note that the Pan servo needs some extra length to rotate.
Original photos (very large): 15A, 15B, 15C
Step 16: Attach Servo Wires
Attach the servo wires to the Pololu board. The Yellow must be on the LEFT. I wire it as Tilt, Pan, Fire, but it's software configurable. Attach the battery pack's power leads. One lead goes to the top of the servos (same wire coloring as the servo wires). The other connects to the board on the lower left, with the Red wire on top. The Serial wire connects at the top, with the Yellow wire on the left.
Original photos (very large): 16A, 16B, 16C, 16D, 16E
Step 17: Completed
Original photos (very large): 17A, 17B, 17C, 17D, 17E
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