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  1. Markwalle17's Avatar
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    New Zealand
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    Feb 18, 2017, 6:06 AM - My Wall-E Build Log #1

    Hi all. This is going to be my 1st post on here after I introduced myself.

    So I'm planning on building a Wall-E around 85% scale and going to be running a track drive setup like Mike's new chain drive.

    At the moment I have the 2x NPC2212 motors, #60 attachment chain and the parts for Wall-E's eyes that Mike Senna shows in his Home depot eye build video.

    Mike Senna chain drive setup.
    https://www.facebook.com/TheMikeSenn...2282741621079/

    Mike Senna Blog
    http://sennaswalle.blogspot.co.nz/

    Click image for larger version. 

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    From looking at the photo and watching the video a couple of times I have worked out this.

    64x Rubber treads (32 for each track)
    64x Steel tread plates I'm going to use1.6mm thick (32 for each track)
    64x Links per attachment chain, Need 4 lengths (2 for each track) #60 Roller Chain With K1 Attachment Link Every 2nd Pitch (Outside Links)
    20x Teeth front wheel sprocket, Need 4 (2 for each track)
    12x Teeth idle wheel sprocket, Need 8 (4 for each track)
    28x Teeth drive wheel sprocket, Need 4 (2 for each track)

    2x NPC-2221 Motor double 1/2″ output shaft (1 for each track)
    11 Teeth motor sprocket, Need 4 (2 for each motor) (Not 100% sure)
    33 Teeth axle sprocket, Need 4 (2 for each track) (Not 100% sure)
    Chain from motor to drive axle, Need 4 (2 for each track) (DON’T KNOW HOW MANY LINKS OR CHAIN SIZE) 35 Pitch chain maybe.
    3:1 reduction motor to drive axle. Motor spins 3 times = drive axle speeds 1 time.

    40 Bottom roller wheels (20 for each track / 10 wheels each side of NPC-2212 motor) 1/8th of an inch lower then front wheel and drive wheel.
    Flange bearings used on the axles for the idle wheels, front wheels and drive wheels.

    I contacted Mike Senna and he has told me he drilled all the holes in the sprockets to make them lighter. Wasn't able to find out the teeth count on the motor to drive wheel.

    -----------------------------------------------

    From watching the video and looking at the photo of the drive system I come up with:

    20 Tooth front wheel sprocket
    12 Tooth idle wheel sprocket
    28 Tooth drive wheel sprocket

    When I look up the size on #60 sprockets I get:
    Front wheel: Size Chain: #60, # of Teeth: 20, Outside Diameter: 5.186
    Idle wheel: Size Chain: #60, # of Teeth: 12, Outside Diameter: 3.249
    Drive wheel: Size Chain: #60, # of Teeth: 28, Outside Diameter: 7.106

    The Wall-E drawings for the outside of the wheels:
    5.750 inch front wheels
    3.375 inch idle wheels
    8 inch drive wheels

    If using them sprockets I get this scale:
    Front sprocket/gear is about right size for 85% scale Wall-E build
    Idle sprocket is about right size for 100% scale Wall-E build
    Drive sprocket is about right size for 90% scale Wall-E build

    I'm guessing Mike Senna just enlarged the sizes of the wheels a little to cover the sprocket and ride up to the tread plates.

    Thinking these sizes sprockets be better for a 85% build:
    Front wheel: Size Chain: #60, # of Teeth: 20, Outside Diameter: 5.186
    Idle wheel: Size Chain: #60, # of Teeth: 10, Outside Diameter: 2.759
    Drive wheel: Size Chain: #60, # of Teeth: 27, Outside Diameter: 6.867
    Hope people can understand this.

    Thanks
    Last edited by Markwalle17; Jul 3, 2017 at 4:12 AM.
  2. RPF Premium Member newmagrathea's Avatar
    Member Since
    Jan 2014
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    Kansas City MO
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    1,177
    Feb 18, 2017, 11:43 AM - Re: Wall-E Track Drive #2

    Oh man, this is awesome. Excited to watch your progress. Welcome to theRPF!
  3. Markwalle17's Avatar
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    New Zealand
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    Feb 18, 2017, 3:50 PM - Re: Wall-E Track Drive #3

    newmagrathea said: View Post
    Oh man, this is awesome. Excited to watch your progress. Welcome to theRPF!
    Thanks dude.
  4. Member Since
    Nov 2014
    Messages
    35
    Feb 18, 2017, 11:24 PM - Re: Wall-E Track Drive #4

    Subscribed and looking forward to this one!
  5. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Feb 18, 2017, 11:37 PM - Re: Wall-E Track Drive #5

    Will post some photos as soon as I can. Just got the plans and some images printed out today.
  6. Member Since
    Nov 2016
    Messages
    107
    Feb 19, 2017, 1:59 PM - Re: Wall-E Track Drive #6

    That is sweet, Ill be following along as well.
  7. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Feb 24, 2017, 12:16 AM - Re: Wall-E Track Drive #7

    Some photos.

    Original I was going to use the 851 conveyor track. But not any more.
    Click image for larger version. 

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    2x NPC-2212 motors.
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    Parts to build his eyes.
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    Waiting on the #60 K1 attachment chain to get shipped to me and looking into ordering my sprockets this weekend.
    Last edited by Markwalle17; Jul 3, 2017 at 4:15 AM.
  8. Wes R is offline Wes R
    Formerly cobalt crimson
    Feb 24, 2017, 12:44 AM - Re: Wall-E Track Drive #8

    Ever since Short Circuit i've had a fascination with robots that have tank tracks and i love the look of this one. Makes me want to build a small scale robobrain from Fallout using that style lol.
  9. Markwalle17's Avatar
    Member Since
    Feb 2017
    From
    New Zealand
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    141
    Mar 11, 2017, 6:06 PM - Re: Wall-E Track Drive #9

    Got the parts for the eyes going together after removing some lips on the parts. Also got the attachment chain yesterday. Still looking into my sprockets that I will get and been looking into info on the axles and bearings to use. Will post photos in a couple of days.
    Last edited by Markwalle17; Mar 21, 2017 at 1:34 AM.
  10. JediMichael's Avatar
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    Nov 2013
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    I live on earth.
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    1,651
    Mar 11, 2017, 9:50 PM - Re: Wall-E Track Drive #10

    Wes R said: View Post
    Ever since Short Circuit i've had a fascination with robots that have tank tracks and i love the look of this one. Makes me want to build a small scale robobrain from Fallout using that style lol.
    I always wanted to have a small little Johnny 5, like the little ones from Short Circuit 2. I wouldn't even know how to built something like that.
  11. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Mar 11, 2017, 10:43 PM - Re: Wall-E Track Drive #11

    JediMichael said: View Post
    I always wanted to have a small little Johnny 5, like the little ones from Short Circuit 2. I wouldn't even know how to built something like that.
    Yeah Johnny5 is cool. Seen them movies a couple of times. There is a Johnny5 builders club: https://groups.yahoo.com/neo/groups/..._Builders/info
  12. Markwalle17's Avatar
    Member Since
    Feb 2017
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    New Zealand
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    141
    Mar 14, 2017, 5:48 AM - Re: Wall-E Track Drive #12

    Very handy little program for making sprockets. http://www.idleamusements.com/?page_id=54
  13. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Mar 15, 2017, 2:59 AM - Re: Wall-E Track Drive #13

    Need to start buying parts for Wall-E.
    Last edited by Markwalle17; Jul 4, 2017 at 2:52 AM.
  14. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Mar 15, 2017, 4:58 AM - Re: Wall-E Track Drive #14

    Been looking into the steel plates size and looks like they are 1.5mm or 1.8mm thick. The thickness of the attachment links is 2.36mm thick. Going to draw them up on weekend and send file off to get them laser cut next week some time.
    Last edited by Markwalle17; Jul 4, 2017 at 2:50 AM.
  15. Markwalle17's Avatar
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    Mar 16, 2017, 3:40 AM - Re: Wall-E Track Drive #15

    Found out today I can get the steel plates laser cut out of 1.6mm thick steel.

    Here is some photos of the attachment chain 4 parts with 32 attachment links on each. Still need to buy 2 connecting links.

    Click image for larger version. 

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    Here is the attachment chain along side the conveyor track. Pretty much center to center on the links.

    Click image for larger version. 

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    Last edited by Markwalle17; Jul 4, 2017 at 2:38 AM.
  16. Markwalle17's Avatar
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    New Zealand
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    141
    Mar 17, 2017, 5:32 AM - Re: Wall-E Track Drive #16

    Attachment chain brought: HERE
    Connecting Link brought: HERE
    Sprockets brought: HERE

    Drive chain brought: HERE
    Drive chain connecting links brought: HERE
    Drive sprockets brought: HERE & HERE

    Been looking into the sprockets for the motor to drive wheel axle. From what I can see the chain is 35 pitch and there needs to be 3:1 drive.

    I have come up with these options. I don't think Mike Senna would have gone smaller then a 10 teeth on the motor. Don't have any good photos of it apart from 1 photo that had a mage of a 33 teeth sprocket in it.

    10 teeth front - 30 teeth rear
    11 teeth front - 33 teeth rear (Cannot find 33 teeth sprockets apart from a aluminum one)
    12 teeth front - 36 teeth rear
    13 teeth front - 39 teeth rear

    Most common ones are 30, 32, 35, 36

    My guess would be 10 teeth front - 30 teeth rear to get the 3:1.

    Got the steel tread plate draw up and emailed off to laser cutters. Just looking into the wheel sizes and sprockets at moment.
    Last edited by Markwalle17; Mar 22, 2017 at 3:30 AM.
  17. Markwalle17's Avatar
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    Mar 17, 2017, 4:36 PM - Re: Wall-E Track Drive #17

    Click image for larger version. 

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    After scratching my head I looked at Mike Senna photo and seen there is 9 treads flat on the ground, 4 flat on the front, 6 flat on the top and 6 flat on the rear. so that helps a little.
    Click image for larger version. 

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    Now looking like this.
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    My Work space. She is keeping a close I on my work.

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    Sprockets are ordered. Ended up just buying the same size as Mike Senna system as the wheels only get enlarged a little and no one would be able to notice it.

    Parts list:

    Chain
    1x RC35-1R-10FT #35-1R X 10FT Standard Roller Chain
    4x CL35 Standard Connecting Link 35-1 (Master Link)

    4x CL60-K1 #60 K-1 Attachment Connecting Link
    1x RC60-1R-W/K1EV2OP-10FT #60 Roller Chain With K1 Attachment Link Every 2nd Pitch X 10FT (Outside Links)
    1x RC60-1R-W/K1EV2OP-10FT #60 Roller Chain With K1 Attachment Link Every 2nd Pitch X 10FT (Outside Links)

    Sprockets
    8x 60W12B 60 Pitch Sprocket 1-1981-12
    4x 60W20B 60 Pitch Sprocket 1-1981-20
    4x 60W28B 60 Pitch Sprocket 1-1981-28

    4x 35B3035A30 Type A Plate Sprocket 1/2" Bore
    4x 35B10-1/2 35B10 1/2" Finished Bore Sprocket (35BS10H-1/2)

    Steel Plates
    80x 190.50mm long 36mm wide 1.6mm thick mild steel (Got some extras for testing)

    Rubber Treads
    Still need to finish drawing CAD file

    I will be uploading the CAD files for any one to use.
    Last edited by Markwalle17; Jul 4, 2017 at 2:47 AM.
  18. Markwalle17's Avatar
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    New Zealand
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    Mar 18, 2017, 2:14 AM - Re: Wall-E Track Drive #18

    Cad file for the tread plates.

    Click image for larger version. 

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    Download DXF: HERE
    Last edited by Markwalle17; Jul 4, 2017 at 2:40 AM.
  19. Member Since
    Oct 2016
    Messages
    70
    Mar 18, 2017, 4:52 PM - Re: Wall-E Track Drive #19

    I love WALL-E it's one of my favourite films. This looks like a awesome build, good luck mate, can't wait to see more.
  20. Markwalle17's Avatar
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    Mar 21, 2017, 1:09 AM - Re: Wall-E Track Drive #20

    Will have the steel plates in a couple of days.
    Click image for larger version. 

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    Sprockets.
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    Last edited by Markwalle17; Jul 4, 2017 at 4:03 AM.
  21. Markwalle17's Avatar
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    Mar 22, 2017, 3:43 AM - Re: Wall-E Track Drive #21

    www.mcmaster.com is another place Mike Senna got some parts for his Wall-E drive system. Got an email from him the other day about the sprockets and collars he is using.

    Will post a list of axles and collars in a couple of days when I have them all worked out.
  22. Markwalle17's Avatar
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    Mar 24, 2017, 10:12 PM - Re: Wall-E Track Drive #22

    Picked up my steel plates this morning.

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    Waiting on my sprockets to get here and looking into ordering axles and a couple of other parts.
    Last edited by Markwalle17; Jul 4, 2017 at 2:43 AM.
  23. Member Since
    Nov 2014
    Messages
    35
    Mar 28, 2017, 1:46 AM - Re: Wall-E Track Drive #23

    Looking really good so far, one wonders what your day job is when you handle these things with such ease. Can't wait to see more!
  24. Markwalle17's Avatar
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    Mar 28, 2017, 1:55 AM - Re: Wall-E Track Drive #24

    Thanks.

    Work in a graphic design shop that designs, prints, screen prints and also embroidery.
    Have done some CAD work in the past on cnc cut aluminum motor cycle parts and computer parts
    as I used to do a lot of custom computer case's and have rebuild a couple of bikes over the years.
    Just finishing off a 2003 Yamaha Blaster at moment with a full strip and rebuild.
    Photos of the quad over here: CLICK

    In 7 Days I will have my sprockets and roller chain. Ordering axles and some other parts tonight for Wall-E.
  25. Markwalle17's Avatar
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    Feb 2017
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    New Zealand
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    141
    Mar 28, 2017, 4:00 AM - Re: Wall-E Track Drive #25

    Axle ordered. Will have some extra keyed shafted after I have cut the parts I need.

    2 Lengths 1/2" X 36" KEYED SHAFTING, 1-2982-50-3
    1 Length 5/8" X 36" KEYED SHAFTING, 1-2982-62-3

    From: http://www.surpluscenter.com/

    Front wheel and idle wheels will be 1/2" keyed Shaft and the drive wheel will be 5/8".

    Got a email from Mike Senna the other day about the axle set screw collars / clamp on shaft collars that he used.

    8x Part: 9414T11 Set Screw Shaft Collar for 1/2" Diameter, Black-Oxide 1215 Carbon Steel
    2x Part: 6435K15 Clamping Shaft Collar for 5/8" Diameter, Black-Oxide 1215 Carbon Steel
    2x Part: 9414T13 Set Screw Shaft Collar for 5/8" Diameter, Black-Oxide 1215 Carbon Steel
    12x Part: 6435K14 Clamping Shaft Collar for 1/2" Diameter, Black-Oxide 1215 Carbon Steel

    He got them from: https://www.mcmaster.com/#

    Tools used to drill the holes in the sprockets: Used a 1 3/4" (45mm) hole saw on the 28 tooth gears and 7/8" (22mm) hole saw on the 20 tooth gears. It took a long time to drill those gears out. Material used on the hubs: Plate steel 1/8" (3mm) to cut out the hub centers for the eight small idlers, Using the 1 3/4" (45mm) hole saw.

    I will not be buying or using these parts as I will be making my own hubs with set screws in them..

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