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This [[Training Ventures|TV]] is tailored for the 152 engineering class. This page will describe the steps of designing and fabricating a vacuum formed shell for the 152 robot. This page will also contain links to sign up for the equipment training necessary for completing this training venture and 152 in general.  

This [[Training Ventures|TV]] is tailored for the 152 engineering class. This page will describe the steps of designing and fabricating a vacuum formed shell for the 152 robot. This page will also contain links to sign up for the equipment training necessary for completing this training venture and 152 in general.  

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[[File:Spray Paint PPE.jpg|1000px|none]]

[[File:Spray Paint PPE.jpg|1000px|none]]

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My first round of spray painting was a metallic gray. As you can see, I was a little heavy-handed and impatient with the spray paint which resulted in drips and pooling. Best practices with spray paint almost always call for thin, light coats for best results. Some of the internal topography proved quite difficult to reach with the spray paint which contributed to the drips/pooling. Luckily, the drips and pooling aren't really visible from the outside of the shell, so it turned out ok. I ended up applying two coats of the metallic gray. After the paint dried, I removed the vinyl masking and the painter's tape around the cockpit. However, I left the vinyl masking for the windows in place. I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

My first round of spray painting was a metallic gray. As you can see, I was a little heavy-handed and impatient with the spray paint which resulted in drips and pooling. Best practices with spray paint almost always call for thin, light coats for best results. Some of the internal topography of my shell proved quite difficult to reach with the spray paint stream which contributed to the drips/pooling. Luckily, the drips and pooling aren't really visible from the outside of the shell, so it turned out ok. I ended up applying two coats of the metallic gray. After the paint dried, I removed the vinyl masking and the painter's tape around the cockpit. However, I left the vinyl masking for the windows in place. I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

[[File:Grey Spray Paint.jpg|1000px|none]]

[[File:Grey Spray Paint.jpg|1000px|none]]

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[[File:Black Spray Paint.jpg|1000px|none]]

[[File:Black Spray Paint.jpg|1000px|none]]

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After the matte black paint dried, I again used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask.

After the matte black paint dried, I removed the final vinyl mask for the cockpit windows. Again, I used Q-tips and isopropyl alcohol to clean up any stray paint that got behind the vinyl mask. And voila! We have created a passing resemblance of Darth Vader's tie fighter. Now all we need is Darth Vader himself...

=Attaching Shell to Chassis=

=Attaching the Shell to the Chassis=

Now, you may be wondering how to attach your masterpiece robot shell to the chassis. Below are two SolidWorks files that can serve as a starting point for connecting the shell to the chassis in a manner that is easily removable. I make no claims that this is the best design by any stretch. In fact, I hope that the 152 students can use their CAD skills from 151 to come up with a better design and share it here for the benefit of their classmates.

Now, you may be wondering how to attach your masterpiece robot shell to the chassis. Below are two SolidWorks files that can serve as a starting point for connecting the shell to the chassis in a manner that is easily removable. I make no claims that this is the best design by any stretch. In fact, I hope that the 152 students can use their CAD skills from 151 to come up with a better design and share it here for the benefit of their classmates.

[[Media:152 Clip 5 M.sldprt|152 Clip 5 M.sldprt]]

[[Media:152 Clip 5 M.sldprt|152 Clip 5 M.sldprt]]<br>

[[Media:152 Clip 5 F.sldprt|152 Clip 5 F.sldprt]]

[[Media:152 Clip 5 F.sldprt|152 Clip 5 F.sldprt]]

These two parts are designed to be 3D printed.

These two parts are designed to be 3D printed.