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The Building of Boomerang | Initial Design | Construction | Completion | |
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| Construction |
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 Boomerang
was developed on plywood first, unfortunately I don't have many pictures
of it. This was my original prototype and you'll notice all the crazy
wires! I had to redesign it because the steering radius was not acceptable. |
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 You
can see the motor mounts a bit better. Also notice the two IFI controllers
- these rock! In the final phase of construction all the parts you
see here will be made out of steel, and all electronics will be installed
on a much smaller area also. |
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 The EV motors and mounts, just sitting on a shelf waiting for use! To the right are some loose wires, to the left, my older 12 volt charger. |
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 Onto the second plywood frame with the proto-wheels attached. This worked very good, got some attention from my neighbors and also laid down some real nice black marks on my driveway! |
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| For
speed controllers I used IFI
Robotics 24 volt Victor
883. These are great for a 24 volt bot that draws less than 30
amps! They are very helpful people, and the controllers are housed
in a pretty descent plastic box with a cooling fan a LED to show you
what is going on. |
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Here are some of the parts cut for the final steel body of Boomerang. These were cut at AP Laser, about 1/8 inch thick. |
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I then did a quick check to see the relation of the batteries ( 4 - 12 AMP hour SLA running at 24 volts) to run the very AMP drawing motors for the estimated 6 minutes of runtime. Batteries were from www.batteryweb.com. |
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 Now it is time to weld, my weld master Dick does some fine work as you can see a close up of a weld of the axle assembly. |
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  Some
of the bottom frame components are installed. Some of the tabs are
for the wheels and axle assembly, others are for the motor mounts.
This is a friction based drive system, nothing too fancy - just like
a boomerang, it is very K.I.S.S! |
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 The welding continues and you can see the base starting to take shape. |
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The base completed and the wheels attached - now it looks kind of a like a skateboard from Hell! |
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Battery placement, these are the four 12 AMP hour SLA batteries that will be used to power Boomerang for roughly 6 minutes. This will also be used for the various weapon systems. |
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  The
sides and top are tack welded on, ready to put down the finishing
bead. I am getting excited now, the bot is finally coming together.
This is where all the CAD work and the laser cutting really pays off,
everything fit just fine! |
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  Of course, here I am right after work ready to build!! |
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 And the final weld, by our weld master Dick (owner and builder of New Cruelty) |
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