At this point, you should have all the parts that you need to make the chassis. Good job! Now we can actually start assembling the chassis! Fun fact: you have drilled 570 holes in total – if you managed to get all the parts done on the first attempt.
The easiest way to assemble the chassis is to make one suspension system at a time. If you repeat the process three times, you will have everything assembled and you only have to connect the frame blocks together.
5.1 First, bolt the absorber attachments to the suspension and frame blocks. Each of the attachments is connected with two M5x8 bolts.
5.2 Next step is to connect the suspension block and the motor block. They’re attached together using four M5x8 bolts and four M5 nuts. I recommend putting in the bolts from inside the suspension block, just like you see in the picture. Tighten everything together and make sure the two parts are aligned.
5.3 Now we need to make some axes for the bearings. Take the 8 mm threaded rod(s) and cut it 8 pieces out of it, each 80 mm long. Finish the cut with a file and a sandpaper, so that the end of the rod is free of any debris. Then, insert the threaded rods into the 8 mm holes inside the frame and suspension blocks. Secure the rods from both sides with an M8 nut. Tighten it, but not too much since the aluminum profile may start to bend.
5.4 Take the 37D motors and mount it inside the motor blocks with six M3x8 bolts.
5.5 Next step is to attach the Pololu 12 mm hex adapters to the motor shafts.
5.6 Now we’ll attach the absorbers. This is done with one M7x30 bolt (on the lower end) and one M3x30 bolt (on the higher end) on each absorber. Use two M3 nuts to fix the absorber in the middle of the M3 bolt on the higher end.
5.7 Next up are the control arms. Attach two of the KFL-08 bearings to each of them. The bearings are attached using two M5x12 bolts and two M5 nuts.
5.8 Next, we’ll assemble the suspension. Loosen both hex screws in each of the bearings and slide the control arms onto the axes. Set the control arms into a distance where they can move freely without interfering with the motor block. Then, tighten the hex screws in the bearings.
5.9 Attach another two control arms to the other side. Same way as before, first loosen the hex screws, then slide the arms onto the axes, then tighten the screws back.
5.10 Now attach four more control arms to the other suspension block.
5.11 Repeat steps 5.1 – 5.10 three times and you should end up with three suspended motor pairs.
5.12 Next, take the 10 mm threaded rod and cut two 500 mm long pieces out of it. Connect the three suspended motor pairs with the 10 mm threaded rods. Secure the frame blocks in place with some M10 nuts. Be careful not to tighten them too much, because once again, this could bend the profile.
5.13 Now, attach the 12 mm to 17 mm hex adapters to the wheels.
5.14 The final step is to attach the wheels to the motors using some M4x22 bolts.