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...... Donut MK II ......

When redesigning the CSS, i wanted to get the maximum possible area for mounting components, particularly the arms. So decided to turn the Rockler "upside down" to get that little extra diameter.

Actually, since i'm in the southern hemisphere, the Rockler is now the same way up as most of you in America do it - it's just the rest of your robot that is upside down!

The centre ring is now bolted to the waist plate, and the outer ring rotates with the torso. This enables the diameter of the CSS to extend to just inside the outer ring.

Showing the position of the old mounting holes and the new size of the centre cutout.

Drilled the new holes to match the outer ring, and enlarging the cutout with the Dremel.

The new cutout shows how much more room is allowable for the CSS. Bottom of the torso may look a bit narrow, but i got a very nice torso from Trent, manufactured in Australia with permission from B9 Creations, it is quite thick and strong, plus all the weight of the other components will rest on the CSS with no pressure on the torso, or donut. But i may still reinforce it just to ensure it can take the bumps while mobile.

Testing the fit before replacing the donut. Found it is actually easier to slide the torso over the CSS if the hole sizes are very close, rather than with a larger gap.

Donut now has the upper 'shelf' removed, and the inside diameter hole increased, to provide a gap to prevent rubbing between the rotating outer ring and the donut. Visible on the bottom of the donut are the old holes for the spacers, and the recesses for the more centrally located new spacers.

New more centrally located holes drilled in the waist plate. They are pretty close to the inside circle, but it is aluminium so should be strong enough.

The Donut in place, and the position of the spacers made from aluminium tube.

With the bearing in place and M6 stainless screws poking upwards, that will go through the torso which will be secured with wingnuts accessible through the sliding side vents.

The base plate of the CSS - currently 6mm acrylic but will probably be replaced by aluminium once the details have been worked out. Note there is no upward pointing screw at the very front, as that would interfere with the programming bay sliding forward when assembled.

Test stack-up of other plates of the CSS, they are a full 16" in diameter.

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