How to build a Ram for Challenge E: Twist-O-Rama

Transcription

1 How to build a Ram for Challenge E: Twist-O-Rama

2 Notes The Ram is like the Structure Tester it is not Interference for a Team Manager or other non-team members to build it. Construction time is approximately 2 hours using a power miter saw and a power drill/driver.

3 Bill of Materials Item BOM Description 8ft of 2in x 4in (5cm x 10cm) dimensional lumber (Select or Premium grade) 1 1.a 1.b 1.c 1.d 1.e 24in (61cm) for RAM Head 20in (51cm) for Ram base 20in (51cm) for Ram base upright 12in (31cm) for Ram base extension 3½in (9cm) for Ram base foot Quantity in (33cm) of 2in x 6in (5cm x 15cm) dimensional lumber (Select or Premium grade) in (7.6cm) Wood screws 2½in (6cm) Wood screws #8 X 2in (6cm) round-head wood screws #8 X 1½in (3.8cm) in round-head wood screws #8 or #10 fender washers /8in (.32cm) X ¾in (2cm) X 48in (122cm) flat aluminum bar 1 6in (15cm) for the Parallel bar 41/8in (10.5cm) for the Ram Stop 1in (2.5cm) cup hooks mouse pad a 8.b 9 10

4 Tools Required Saw Handsaw, Table saw, Power miter saw (all can do the job, but the power miter saw is preferable)

5 Tools Required Hacksaw for cutting aluminum bar

6 Tools Required Drill with 1/16in (.625cm), 1/8in (.32cm), 11/64in (1.72cm), and 3/16in (1.87cm) bits.

7 Tools Required Screwdrivers (screwdriver bits strongly recommended)

8 Tools Required Tape measure and pencil

9 Tools Required Square with a 12in (30.5cm) or longer straightedge

10 Tools Required 2 clamps not necessary, but helpful

11 Tools Required Wood Glue Rubber mouse pad

12 Select and Cut Lumber The 2in x 4in (5cm x 10cm) and 2in x 6in (5cm x 15cm) boards need to be straight and free of twists. Taking an extra minute or two to carefully select them will save you a lot of time and effort later. If lumber yard or home center provides a cutting service and you are uncomfortable with power saws, get them to do the cutting for you. It is best to cut the longest length first, then the next longest, and so on. If there is a mistake, there will be enough remaining length for a second chance.

13 Select and Cut Lumber Cut the 2in x 4in (5cm x 10cm) lumber into the following lengths: 24in (61cm) for the Ram Head 1 piece 20in (51cm) for the Ram base support 1 piece 20in (51cm) for the Ram base uprights 2 pieces

14 Select and Cut Lumber

15 Select and Cut Lumber Cut the 2in x 4in (5cm x 10cm) lumber into the following lengths: 20in (51cm) for the Ram base support 1 piece 20in (51cm) for the Ram base uprights 2 pieces

16 Select and Cut Lumber For actual length Each Ram must be custom fit to each Tester Base Measure the height of the Tester Base from floor Add 16-5/8in (42.23cm) to the Tester Base height Subtract this number from 21½in (54.6cm) Remove this amount from each 20in (51cm) upright For example if the Tester Base = 3½in (8.9cm) the formula would be [21½in (54.6cm) (3½in (9cm) /8in (42.23cm) ) = 1-3/8in (3.5cm)]

17 Select and Cut Lumber Cut the 2in x 4in (5cm x 10cm) lumber into the following lengths: 12in (30.5cm) for the Ram base extensions 3 pieces

18 Select and Cut Lumber Cut the 2in x 4in (5cm x 10cm) lumber into the following lengths: 4in (10cm) for the Ram base feet 3 pieces

19 Select and Cut Lumber Cut the 2in x 6in (5cm x 15cm) lumber into the following lengths: 13in (33cm) for the Ram base top support member

20 Base Assembly On the 20in (51cm) base piece, mark 5in (13cm) in from each end. Use a square to extend the mark across the wood.

21 Base Assembly Place the Ram head in a separate location from the others so it will not be accidentally used for another purpose.

22 Base Assembly Align one end of each upright with the base on the outside edge of the line.

23 Base Assembly Drill 2-3/16in (1.87cm) pilot holes about 2 1/4in (5.7cm) deep through the Ram base and into the end of each upright.

24 Base Assembly Secure with 3in (7.6cm) screws into the holes to secure the upright to the Ram base.

25 Base Assembly The distance between the inner faces of the uprights should be exactly 10in (25.4cm).

26 Base Assembly Place 2in x 6in (5cm x 15cm) Ram base top support member onto the top of the uprights so that the edge of the 2in x 6in (5cm x 15cm) is aligned with edge of 2in x 4in (5cm x 10cm) uprights.

27 Base Assembly Drill 2-3/16in (1.87cm) pilot holes 2¼in (5.7cm) deep through the Ram base top support and into the end of each upright.

28 Base Assembly Secure with 3in (7.6cm) screws into the holes to secure the upright to the Ram base top support.

29 Base Assembly Align 2-12in (31cm) Ram base extensions at the ends of the Ram base so the extensions extend in the opposite direction of 2in x 6in (5cm x 15cm) overhang.

30 Base Assembly Secure the Ram base extensions to the Ram base with 2 2½in (6.4cm) wood screws for each upright piece.

31 Base Assembly

32 Base Assembly Align the remaining 12in (31cm) Ram base extension in the center of the Ram base between the uprights facing the opposite direction of the previous Ram base extensions. Secure with 2 2½in (6.4cm) wood screws.

33 Base Assembly Secure the Ram s feet to the upright pieces with 2 2½in (6.4cm) wood screws each.

34 Base Assembly Cut the mouse pad to fit each foot and at each end of Ram Base. Secure the pads to the undersides of the feet and the Ram base ends with wood glue. This should provide protection for floor surfaces.

35 Aluminum Parallel Bars Using a hacksaw, cut 2 pieces of bar 6in (15.25cm) in length.

36 Aluminum Parallel Bars

37 Aluminum Parallel Bars Tape the 2 pieces together flush.

38 Aluminum Parallel Bars Using an 11/64in (1.72cm) drill bit, drill holes 3/8in (1cm) from each end, centered between the edges.

39 Aluminum Parallel Bars Using a 1/8in (.32cm) drill bit, drill 2 holes in the overhanging edge of the Ram base top support. The holes should be ¾in (2cm) in from the outside edge and centered top and bottom. The holes should be roughly 1in (2.5cm) deep.

40 Aluminum Parallel Bars 1 On each of the #8 round-head wood screws, place: A fender washer 2 One of the parallel aluminum arms (from the first step) Add another washer to space 3

41 Aluminum Parallel Bars Drive the screws with their parallel arms into the upright pieces until the arms are snug, then back the screws out ¼ turn each.

42 Aluminum Parallel Bars

43 Hang the Ram Head Measure the distance between the roundhead screws driven into the Ram base top support. The distance is center-to-center. (Tip: Left edge to left edge, or right edge to right edge produces the same result if your eye can t find the center.)

44 Hang the Ram Head Subtract this distance from 24 inches (61cm). Divide the result by 2. Mark the top edge of your Ram head this distance in from each end. Find the center between the edges.

45 Hang the Ram Head Using a 1/16in (.625cm) drill bit, drill shallow starter holes for the cup hooks.

46 Hang the Ram Head Screw the cup hooks into the holes, lining them up so the hooks are across the Ram head, in opposite directions.

47 Hang the Ram Head

48 Hang the Ram Head Drive a #8 x1½in (3.8cm) screw in line with the cup hook holes, one inch from each end, leaving ¾ in (1.9cm) of screw exposed. These are the pull and release handles.

49 Hang the Ram Head

50 Hang the Ram Head Hang the Ram head from each of the parallel arms. On a level floor, the Ram head should now also be level. Small adjustments are possible in the cup hooks themselves.

51 Ram Stop The amount of Ram head drop, and thus the amount of energy delivered, has been set at 3in (7.6cm).

52 Ram Stop Measure on the remaining piece of aluminum bar 4 1/8in (10.48cm) from one end. Using a hacksaw, cut the Ram Stop from the aluminum bar.

53 Ram Stop Drill a 11/64in (1.72cm) hole ¾in (1.9cm) from one end of the Ram Stop.

54 Ram Stop On the Ram base top support measure 6½in (16.5cm) from the end and mark it. Draw a line vertically on this mark.

55 Ram Stop With the Ram head at rest, align the Ram Stop so that the edge without the hole is 3in (7.6) above the top of the Ram. Mark where the hole in the Ram Stop is along the vertical line.

56 Ram Stop Drill a 1/8in (.32cm) hole into the Ram base top support.

57 Ram Stop Secure the Ram Stop to the Ram base top support with the remaining #8 round-head wood screw.

58 Completed Ram