View Full Version : [Contest Entry] Rise of the machines T-1

11-07-2008, 10:25 PM
This is my second entry into the TRC contest, This robot is a hard one to build from scratch as there are very little photo's on the net, I have searched for about 5 months and only come up with about 9 good res pics. GWJax found a good pic for me as well [far right in pic]. There are a number of sites dedicated to the Terminator series, but not a lot on the T-1 so I think that I will be doing well to complete this robot. It will be similar to J5 in as much that it will have an ITX PC and solid state Hdd and vision, quite a few sensors will be included, but the main attraction will be the live twin firing gattling guns which GWJax is building for me, These will be in the region of 10-13" long and will rotate at a pretty rapid rate, there will be a fair bit of timing to be done to get this right on GW's part. The base and tracks are finished, Two sets of batteries will be housed in the track sections, [Penty of room in there] and the main batteries in the mid section. At this stage I have built the main body in MDF and balsa, this is the plug that will be used for the mold to cast the final item in either glass or carbon. The head will be carved out of molding clay that GW is going to send me and then molded in glass to form the head, this will house the sensors and camera. T-1 will have a total of 12 servos, 6 HR-5990 for the arms and gattling guns, 2 HR- 5990's for the raise and lower of the torso, Two heavy duty 1/4 scale servos, one for the rotational base and one for the rear track steering, and 2 for the pan/tilt head, 645's. Track will run of 12v system [ May reduce this to get a lower speed], 9.6 ITX and 7.2v servos. I have not decided on the targeting system for the gattling guns yet. I hope this robot will be ready for the next round of competitions, but, if it is not then it will have to go in the next round.

Now that my T-1 competition has finished I am switching over ALL info on this project to contest entry Here.

T-1 Rise of the Machines


Part 1


Nylon 1-15/16" bushings from lynxmotion, two joined together.


Hex 1-15/16 nylon standoff's joined together.


Jig set up for hex rod to get correct length.


Jig in use for cutting hex rod roughly to length.


Next stage is to sand the edge of the hex rod to get it square.


Nylon rod in jig cutting roughly to size.


Trimming to the correct length.


Nylon tubes ready for the next stage. Lynxmotion part [ Here (http://www.lynxmotion.com/Category.aspx?CategoryID=43)]


Hex rod ready for the next stage. Lynxmotion part [ Here (http://www.lynxmotion.com/Category.aspx?CategoryID=43) ]


Using a machine vice to hold 4/40 rod @ 25mm long, These will be used to join the hex rod together.


Using a Dremel with a diamond cutting wheel to cut 4/40 threaded rod.



Black Polycarb 5mm sheet, These will be used for the track sides and base.


Track sides, Two large holes are for the motors, medium holes are for bearings and smaller holes are for the nex rod to join the sides together.


Track sides in vice for cleaning up.


Lynxmotion Idler hub-13 [ Here (http://www.lynxmotion.com/Category.aspx?CategoryID=94)] for 3" [ 75mm] Tracks.


Lynxmotion 75mm track link [ Here (http://www.lynxmotion.com/Product.aspx?productID=512&CategoryID=94) ]


Lynxmotion 50:1 gearhead motors 12v [ Here (http://www.lynxmotion.com/Category.aspx?CategoryID=11) ] These are fitted to the polycarb sheet.


Sabertooth 2 x 10 H-Bridge motor driver [ Here (http://www.lynxmotion.com/Product.aspx?productID=562&CategoryID=10)] This will be used for the Lynxmotion 50:1 motors.


Sprocket set SPRK-02 [ Here (http://www.lynxmotion.com/Product.aspx?productID=544&CategoryID=94) ] frpm Lynxmotion, AA batery for size comparison. you will need 8 of these.


Close up of the Nylon tube, These are what the tracks glide on.


Close up of 50:1 12v motor.


Close up of one set of sprockets with idler joining the two together.


One side temporarly put together to show you the setup.


As you can see with this clear polycarb set up, All the sprocket gears and rollers, The final set up will be black polycarb and there will also be a polycarb platform in the middle so that I can insert my battery pack either side.


Another side view.


Ok, This is the start of the track construction process, Because I am using the 3" tracks there are no hex rods that Lynxmotion sell at present that are long enough, so I have used 1 1-15/16 rod and cut down another 1-15/16 hex rod and tapped with a 4/40 so as to join them together.


Hex rod now joined together, you will need 8 of these.


Joining the polycarb sides together. I used 5/8 x 3mm cap bolts.


End view showing the nylon tube inserted over the hex rod.

11-10-2008, 11:38 AM
Part 2


Polycarb 5mm sheet for track sides.


This part is the platform between the track sides for the batteries.


The shaft on the left side needs to be cut off for the modification for the 3" track system.


Cutting process started.


Universal Hub-02 [ Here (http://www.lynxmotion.com/Product.aspx?productID=114&CategoryID=94)] has two small protrusions either side of the flange, One side needs to be sanded flat [Or turned on a lathe] for the modification.


Left shaft cut off.
Because there are no pre made parts for the 3" track system you have to modify the existing Idler hub, I had to cut of one end as seen in the pic.


Sanding the idler flush.


Drilling out the existing holes so as to tap for 3mm thread.


1 set of tracks temporarly put together, these track sides will be changed for polycarb black sides.


Tracks temporarly fitted.


25mm x 25mm x 2mm alloy for the track base/sides.


Base fitted to track sides.


Ok, These are the new Black polycarb track sides, these replace the clear sides i had before, also note the the sides are a different shape at the front and rear, these were modded after finding better pics of the real machine.


These are the two battery plates that fit inbetween the track sides.


Hex standoff's and battery plate installed.


Nylon tube added to hex standoff's.


Sprockets added to front and back.


One track completed.


As you can see the battery fits real neat into this area, This will be used for the servos and the other side will be used for the Pico ITX.


One track completed.


Base plate fitted to both track sides.


Now to the interesting part, Making the plug for the fiber glass lower body molding. Above pic are two MDF [Medium Density Fiber Board] As you can see i have marked out the sides for fret sawing out, bottom one has been fret sawed. Next clean it up so you have a neat jig, this will be used as a template for a router.


both MDF patterns made and ready for the router machining.


Fret sawing out the polycarb sheet.


Ready for the router.


Polycarb marked out from the template and roughly cut out with a fretsaw.


Jig was bolted to the polycarb sheet and a router used, the straight cutter has a ballrace at the bottom of the cutter, this in turn runs around the MDF pattern and the cutter machines the polycarb to a nice finish.

11-13-2008, 03:44 AM
Part 3


This is another jig for the base section of T-1, Section in the center will be removed, This is where the ball race will be housed.


Again using the router to get a nice clean hole.


Ready for the next stage.


Make an outer ring out of MDF, This is for the raised area on top of the bearing platform.


Outer ring glued to the bearing plate.


As you can see I have now glued the top bearing plate to the MDF sides, this whole jig will be used for the final plug to make the mold for the lower body section.


Jig on top of the T-1 track base.


Starting to look like the real thing from the pic.


Rear shot and tape measure for size comparison.


We need a cardboard template of the front lower front section to see if this looks right draped over our jig.


A comparison against the pic top right.


My balsa wood stack, this is used to cover the MDF jig.


Using my fret saw to cut the maked out balsa from the cardboard template.


First layer of 6mm balsa glued to jig with cyno glue.


More balsa layers.


Keep adding layers.


Last layer at the bottom of the jig.


Top section of pattern has been cut, this top section will be used for our second layer on top first layer forming a double skin and raised panel.


This is the section we will use for our template to cut the next balsa section.


Templates used to mark out our next cuts on our balsa, A pair of scaling dividers is essential in making these models for acuracy.


Sections cut out for the next gluing session.


Next, to glue on the jig.


As you can see top layer has now been glued in place.


Comparison photo just to see if I am on the right track, it is quite weird, the eye does not always pick up defects, but when you put a photo in the pic you can see any flaws you have made.


Close up of lower body.


Filling in on the underside of the lower body.


Using car bog around the inner edge to form a radius.


Close up of bog on both inner and outer edges.


Rapidfilla used for the radius on the balsa, this is used because it is softer than balsa, when sanding we don't want to gouge out the balsa, so the filler will sand first.


Close up of filler.

11-13-2008, 06:08 AM
4mem8, you are one talented model builder!

I'm in awe of how you can just take some pictures and build this thing from scratch, I really appreciate the way you catalog the entire process so the noobs like me know how it's done !

Great work!

11-13-2008, 12:20 PM
Hey Scud, Many thanks for you comment. It;s comments like this that make me want to do even more for this community. I enjoy this type of work and if it helps out other ppl here then I have done my job the best I can. This project will be a long one, These are just the plug building processes, I have to make female molds of them and then cast the real items, so I will be posting the full process for all of this. Just takes time. Next year I will be learning C# I hope it will sink in, as I need to learn this for my bots. Molding I can do Programming I can't, so to be good at both is my dream. Footnote: GWJax and my self have some real neat projects coming up later next year that you will all love.

11-13-2008, 12:57 PM
wowzas!!!!!! that looks awesome!

11-13-2008, 01:00 PM
Thanks elios, appreciated.

11-13-2008, 11:00 PM
Part 4


Underside showing filler for curved edges.


Close up of filler and curved edges.


Starting to take shape now, Alloy disc is the bearing plate for the top body. Also I still have to do some work on the lower front section.


Closer view, Don't forget that this is only the plug for the fiber glass mold.


Side view.


Front view, Lower section has to have some cosmetics done.


Real T-1 pic to show comparison, Also note lower body mods.


Slight angle shot to give a better view.


Close up of front section, also the rebates have been added in the opening.


Close up of the front section.


Marking out the upper body section, A pair of dividers is essential for this operation.


Cardboard template upper body section, checking to see from the pics if the shape is right.


Rear view, looking good.


MDF templates for the balsa skin as in the lower body section.


First stages of the balsa layup, top section is where the head will go.


Next section, Note the the lower horizontal cuts in the balsa, These are so it will bend and follow the contour of the jig.


Starting to take shape.


This is the second to last bit to go on the bottom of the jig, I am putting a series of cuts horizontally so the balsa can bend around the jig.


Note how easy it is to follow the contour of the jig when cuts are made.


Last lower section to go on, cuts are now closer together for a tighter radius.


Upper body section balsa now glued in place ready for filling.


Comparing the two body sections.


Upper body section now ready for the rear balsa laminates.


Cardboard template for the rear head section,


Side panels removed as this pattern now becomes the top raised panel section. a 6mm sheet will take the form from the top shoulder to the 2nd pen line above the tape. Once this is glued in place on top of what we have already done this becomes the faceted area on the sides.


Rear section of the neck area, This was the hardest to do as I have no documentation on this part, but I think it is close.


Upper body section temporarly in place to check how it looks.


Starting to take shape now, This project is now getting exciting.


Filler added, ready for sanding.


Upper body section now has it's second layer, this is used to reproduce the curved fairing, It is rough filled at this stage.

11-13-2008, 11:01 PM
Part 5


These sections are for the raised neck area which will be back filled for a radius.


As you can see we now have all the neck sections glued in place.


Lower radius now refilled to a larger radius and the neck area also filled.


Close up of neck area.


Rear neck area being built up with balsa wood.


Rear side angle shot showing the complex curve.


Profile curves for the radius back filling, Note the beveled front edge, Critical for a smooth finish.


Rear has now been radiused.


Starting to take shape now.


Take away the MDF supports and you can see that it is getting close to the required shape.


Front/side view.

This is all I have to date, more pics when i have done some more work, This project could take up to another two months or more as there is a lot of work ahead yet to be done.

11-14-2008, 12:35 AM
wow this is amazing work 4mem8! do you need any help this weekend as i will be just round the corner working on some old austin 7's?

11-14-2008, 12:53 AM
wow this is amazing work 4mem8! do you need any help this weekend as i will be just round the corner working on some old austin 7's?

I have a couple of hrs spare Saturday afternoon, 2-4pm call around.

11-14-2008, 01:30 AM
awesome, nothing is set in stone. Ill bring my workings on WidowMaker round as well, if i come round... i cant really do anything until i get 2 servos. ill be at number 14 (you know where)

11-15-2008, 01:46 AM
More updates to part 5 on page 1

11-17-2008, 01:43 AM
T-1 Rise of the Machines

Part 5

More updates from the weekend.


Fitting the bottom in place.


This is the area where the rotational bearing will go. Has to have a 10mm spacer under the alloy ring.


Other half of the rotational bearing plate on the main body. This area will be fiber glass or carbon when cast.


10mm balsa spacer, this will be cast into the fiber glass mold


Alloy bearing plate on top of spacer.


Disc on the end is for the spring system.


Another angle of the disc.

11-17-2008, 01:54 AM
Actively watching your fantastic progress 4'8. I'm eagerly looking forward to the casting process. Any tips you that throw in about working with fiberglass would be appreciated.

11-17-2008, 03:09 AM
metaform3d: Sure, I will be doing a full tutorial on this when the time comes, Which will not be to far away.
Products that will be used are:
[1] Polyester resin for the mold
[2] Fiber glass tissue: First lay up after the gelcoat.
[3] 200g chopped strand matt: Second lay up after the tissue.
[4] 400g chopped strand matt: Third lay up after the 200g Matt.
[5] Release wax: used to polish the mold and prior to laying up.
[6] Release agent: PVA based liquid so glass does not stick to mold.
[7] Gelcoat: Used in the first coat in the lay up.
[8] Plastiscene: filling in gaps when making the box to hold the mold.
[9] MDF fiber board: Making jigs to hold the plug.
[10] Polyester thinners or acetone: Washing brushes and thinning.
[11] Duratek: Used for spraying into the mold then lay up, to get a smooth gray finish, Also used for the final finish on plugs.

11-19-2008, 05:15 PM
Hi 4mem8,

I really enjoy following your well documented project. Very impressive wodcraft.

Keep up the great work!


11-20-2008, 12:33 AM
Thanks Zenta, Pleased you are enjoying the project.

11-25-2008, 10:59 PM
I have not had a lot of time this last week, so not much of an update, but what I can say is that I have got the materials to start the two box's that house the two lower and upper torso body molds, I will try to get some pics of the process this weekend.

11-25-2008, 11:36 PM
Please do! I am really looking forward to learning about this process.

11-26-2008, 09:22 AM
As always, your craftsmanship is amazing! I look forward to reading your updates on this project. Your T-1 base is a beautiful work of art... I guess your Wall-E will have a big brothers soon! ;)

11-26-2008, 10:42 AM
Ha ha, Tom, Yeah I guess your right, Out sized and out gunned. just hope I can make it intelligent as well.

11-28-2008, 03:57 PM
Ok, another small update on T-1, Things are going to be a bit slower for a while as I have to renovate the bathroom so time will be split between that and my T-1. Below are a few pics of the beginning of my fiber glass molds for The upper and lower body shells, We first have to finish the plugs to a smooth finish, I have used an MDF sealer to fill the balsa till it is quit hard, then sand back, Next I used Plastikote primer laquer based for quick drying times, Sand this back until you are happy with the results. Next make two MDF box's, These will house the two upper and lower plugs, Next we have machined some MDF support blocks, These will go as close to the body plus as possible, This will support the 3mm MDF platform we make. The 3mm platform will be contoured to the shape of the body shells any gaps can be filled in with plasticene.


Upper and lower body plugs have now been primed with a sandable laquer filler.


MDF box for holding the upper body shell, The upper body is placed on it's side in the box.


These MDF supports will fit around the upper body shell.


Upper body plug in the box ready for the MDF supports.


Notice that the MDF supports are as close as you can get them against the body, These will support the 3mm mdf which will be contured against the body plug, This is to form a platform to which the fiber glass will be laid on to form a flange.


Bottom view of upper body plug.


Larger MDF box for the lower body plug. The same process will occour as for the upper body plug.


Lower body plug, with supports ready for the 3mm MDF platform.

12-07-2008, 11:45 AM
Damn, Having to do some bathroom repairs, Nearly fell through the floor into the basement, Just found out that the floor is rotten through the shower leaking over time. $3,000 $ fix Argh, T-1 on hold for a month. Damn it.
Just an up date to my T-1, Unfortunately there is going to be a Bigger delay than expected in any more progress for a while, I have found more problems in our bathroom, The floor rotted out more than we thought via the shower and we now have a $5000 bill to repair it, and that's doing all the work myself, So ripping up the floor and new shower and spa is costly , so robotics is on hold for a while guys, Sorry.

12-13-2008, 12:23 PM
Just an up date to my T-1, Unfortunately there is going to be a Bigger delay than expected in any more progress in T-1 for a while, I have found more problems in our bathroom, The floor rotted out more than we thought via the shower and we now have a $5000 bill to repair it, and that's doing all the work myself, So ripping up the floor and new shower and spa is costly , so robotics is on hold for a while guys, Sorry.

12-13-2008, 03:57 PM
grrrrrrrrrr bad 4mem8.... robotics should take principle!! :P
make sure your on the chat forum tonight - or all hell will break loose!!!

12-14-2008, 12:09 AM
elios: I can only try, but when you do not have a shower or a bath this is more important than robotics, Priority, You will learn this later in life.

03-13-2009, 10:07 AM
Hi 4mem8,

I was wondering how your shower is coming together. Any news on this project?


03-14-2009, 06:16 PM
Hi Xan, Sorry for being out of here for some time, yes it is a big job the renovation of our bathroom, But is half finished but looking good. I also had another problem, My server crashed disabling ALL my other pc's and could not afford to rebuild it until now, just got it online a few days ago Zan, so robotics has been on hold. But will get back to it as soon as i can. How are your projects going Xan ? good I hope. keep me informed Please.

Also sorry to all here for not getting back to you all regarding progress, missed you all and my other friends as well, hope to be back soon . just have to do a bit more work on my server and bathroom then will be back in full swing , I bet a lot has changed in the 4 months I have been away guys. Fell free to update me of news ty.

03-16-2009, 10:08 AM
Hi Mike,

I’m happy to hear that your bathroom is coming together. I understand that your bathroom got a higher priority then robotics at the moment. It could get really smelly if you placed the priority the other way around. ;)

I’m also sorry to hear your server crashed.

Private life kept me busy for some time just like you. I had some robotic time but not as much as I wanted to. I think you know the feeling ;)
I did a sidestep to another project including a rover with arm. This will be posted later on. The phoenix code is also improved in both speed and accuracy. This will allow me to include terrain adaption.

I would be happy to see T1 getting finished :)


03-16-2009, 02:03 PM
Hi Xan, good to hear you are still experimenting and that u have improved your phoenix code, love to see some vid when u have time.

03-17-2009, 10:04 AM
Hi Xan, good to hear you are still experimenting and that u have improved your phoenix code, love to see some vid when u have time.

Iím planning to shoot some vids this week.

03-31-2009, 03:12 PM
Hi, some interesting T-100 photos here

http://translate.google.com/translate?prev=_t&hl=en&ie=UTF-8&u=http://robot.watch.impress.co.jp/cda/news/2009/03/25/1678.html%3Fref%3Drss&sl=ja&tl=en&history_state0= (http://translate.google.com/translate?prev=_t&hl=en&ie=UTF-8&u=http://robot.watch.impress.co.jp/cda/news/2009/03/25/1678.html%3Fref%3Drss&sl=ja&tl=en&history_state0=)

04-01-2009, 02:53 PM
Hey Orac, Thanks so much, have not seen this site, helps a lot. Mike.

04-03-2009, 12:33 PM
Amazing work. Amazing on-the-fly engineering, amazing talent. Wow and more WOW!
Yamaha XV1700A (http://www.cyclechaos.com/wiki/Yamaha_XV1700A)

04-05-2009, 07:54 AM
SN96, Thank you, Appreciate your comments. It is a lot of work but it will be awesome when finished, plan to restart work on it soon.

06-05-2009, 01:59 AM
HI EVERYONE, SO SORRY FOR THE LONG DELAY IN GETTING BACK TO MY T-1. Had bigger problems than expected with my bathroom and server crashing. Also now out of work due to the downturn recession worldwide, so funding of my robotics has ceased, but have enough materials to continue without sinking to much into them at present. so I will try to continue where I left of which is the molding process's, give me another week to get organized, pics will be a bit slower in coming till I get back up to full speed on T-1. Good to see all you guys are getting into full swing for the Robo games. GOOD TO BE BACK GUYS.

06-05-2009, 06:19 AM
Good to hear, now the latest film is out will you be tempted to build one of the latest T bots :)

06-05-2009, 07:29 AM
orac: Please don't tempt me. Please, I have enough on my plate as it is :))), but no doubt it will get the better of me.

06-05-2009, 05:57 PM
Welcome back Mike. Good to hear your well!

06-05-2009, 09:46 PM
Glad to see you are back on the bots! Sorry to hear about the job, I know the feeling, Unfortunantly my parents both lost their jobs recently so I know its getting bad, I had no idea it was getting bad abroad as well tho, I thought it was just us gluttonus americans and our suvs! Again Bummer to hear Hope T-1 goes well. Get us some pics darn you! hehehe

06-07-2009, 08:51 AM
ha ha will try nagmier, but cannot promise at this stage . Do my best.

09-23-2009, 05:17 PM
ok guys i know i have been away for a while and things here in New Zealand are bad after the recession, still no job yet grrrr. but i need to get back into my robotics to take my mind of other things, so will try to do a bit more on T1

09-23-2009, 05:23 PM
swell my friends it's been a long time since i did any work on T1, but i have been depressed as of late with no job for 3.5 months here in NZ so had lost interest in my projects. but on the flip side am now getting more interested, so hope i can continue where i left off, but don't expect any pics soon. have to find where i last left off guys he he .

Macro Man
09-24-2009, 10:33 AM
I just found this thread, some fantastic work there! :)
Your Wall-E rocks too!

09-24-2009, 11:59 AM
Welcome back!

It had been a while we hadn't heard of you!

Good to see you too! :)

Sorry for your job.


10-16-2009, 12:52 AM
Macro man,Nagmier and Sam, Yeah nice to be back, but when u have stopped for 5 months and trying to pick up where u left off it;s damn hard, so trying to organize myself as to where i left off. I will be watching this forum though even if i dont get any more up to date pics of my projects.

10-16-2009, 03:22 PM
4mem, great to have you back!!!
BTW- you left off doing some way cool builds:)

10-17-2009, 09:25 AM
Hey thanks ooops , yeah those builds lol , in dust somewhere, gets shovel to find them, covers other robots behind me lol.

10-17-2009, 09:32 AM
welcome back 4mem!!! We still need to have that crysis session ;)..

anyway why are you up at 3.30 am in the morning like moi...?

10-17-2009, 10:59 AM
4mem8 and Elios!

Long time no see! Good to see you here.

I heard crysis? hmmm

I have to say your 'bots were really cool 4mem8, can't wait to here how it'll continue.

10-17-2009, 11:33 AM
yes you heard right.... lawl. i have been 'round, i been trolling. Working on setting a world record... ;)

i still cant beleive i'm up, or that mikes up.... its soo damn early in the morning... especially for a teen ager...

10-17-2009, 03:38 PM
hey Elios, i might ask the same thing lol, my excuse is i am older and can't sleep. good to hear from you.

10-17-2009, 07:24 PM
you well 4mem? If you want some help programming or anything you have my email, and I think you have my number, so just gimme a buzz

10-07-2011, 01:24 PM
Omg Elios, i so need to get back to my robotics its been to long away from this forum and all the nice ppl here. T-1 is still sitting there lol i keep looking at it. i really want to get back itto it again. so much catching up to do .

10-15-2011, 09:55 AM
Wow what a great project, truly inspiring!

10-16-2011, 11:05 PM
Ty Abacus, appreciated.:-)

05-10-2012, 02:02 AM
Hi guys have been pottering in the basement doing a bit on T1 but need more dedictaed time to get ahead keep yu all posted.

10-26-2012, 03:59 PM
Im still pottering on this machine, have had no time as of late but i really want to finish this project, to to those that were following me and this project im sorry for the delays. i will get back to it i promise. :wink:

11-04-2012, 05:26 PM
Have you seen this video of it?


11-07-2012, 12:14 PM
WOW ty so much Orac awsome video ill treasure it when continuing my build. :-) can you re-embed it it stopped working . ty .