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Introduction

You will be using many of the skills you have learned throughout the build process so far.

  1. Next we will build the polyfuse adapter for the battery tubes. Start by removing the paper backing from both sides of the acrylic pieces.
    • Next we will build the polyfuse adapter for the battery tubes.

    • Start by removing the paper backing from both sides of the acrylic pieces.

    • Super glue one of the positive battery terminals to the acrylic piece.

    • Be sure the smaller hole is in alignment with the gap in the piece. This will ensure the polyfuse fits well.

    • When working with cyanoacrylate (super glue) it is recommended that you wear gloves, safety glasses, and work in a ventilated area.

  2. Bend the leads of the polyfuse perpendicular to the fuse in opposite directions. Place the polyfuse into the gap in the acrylic piece.  The fuse leads should fit easily through the holes on each side of the adapter. Place the other button terminal on the acrylic with the lead of the polyfuse going through the small hole.
    • Bend the leads of the polyfuse perpendicular to the fuse in opposite directions.

    • Place the polyfuse into the gap in the acrylic piece. The fuse leads should fit easily through the holes on each side of the adapter.

    • Place the other button terminal on the acrylic with the lead of the polyfuse going through the small hole.

    • Make sure that the metal battery terminals aren't off center enough to keep the adapter from fitting in the battery tubes. Test fit them if you are unsure.

    • Use superglue to hold this button terminal in place.

    • Ensure that the polyfuse leads are not touching each other when packed into the gap!

  3. Bend the polyfuse leads onto the battery terminal and solder the terminals.  It important that the terminals lay flat and the solder is not higher than the center off the terminal which could make the battery connection intermittent. Be careful when soldering the battery terminal as it will be very hot. Repeat this process for the other battery adapter.
    • Bend the polyfuse leads onto the battery terminal and solder the terminals. It important that the terminals lay flat and the solder is not higher than the center off the terminal which could make the battery connection intermittent.

    • Be careful when soldering the battery terminal as it will be very hot.

    • Repeat this process for the other battery adapter.

  4. Sand down the top of the base of the spring terminal. Do a corner that is adjacent to the smaller of the holes. Solder on a glob of solder on the sanded portion of the spring terminal.
    • Sand down the top of the base of the spring terminal. Do a corner that is adjacent to the smaller of the holes.

    • Solder on a glob of solder on the sanded portion of the spring terminal.

    • Do this for both battery terminals.

  5. Place the internal structure into the shell. This is for measurement and alignment purposes for the following steps.  Do not place your shell permanently onto the motor structure just yet.
    • Place the internal structure into the shell.

    • This is for measurement and alignment purposes for the following steps. Do not place your shell permanently onto the motor structure just yet.

  6. Align the round irregular shaped piece with the holes in the square piece. Cement together and set aside, the rest will not be cemented until the battery wires are routed.
    • Align the round irregular shaped piece with the holes in the square piece.

    • Cement together and set aside, the rest will not be cemented until the battery wires are routed.

    • When working with acrylic cement it is recommended that you wear gloves, safety glasses, and work in a ventilated area.

  7. Grab your end cap piece and slide the starboard side wires through the hole. Make sure you slide the piece on the wires, square piece first. Slide the acrylic piece on with the wires going through the holes.
    • Grab your end cap piece and slide the starboard side wires through the hole. Make sure you slide the piece on the wires, square piece first.

    • Slide the acrylic piece on with the wires going through the holes.

  8. Make sure your end cap is flushed against the shell and is next to the slit marked in image 1. Pull any slack from behind the end cap so it's a comfortable length without it being too taut. Also make sure the acrylic is oriented as shown in image 1 with wires coming from bottom. Hold that end cap piece at its designated length and drag along the circular pieces to it. Make sure it is concentric.
    • Make sure your end cap is flushed against the shell and is next to the slit marked in image 1. Pull any slack from behind the end cap so it's a comfortable length without it being too taut.

    • Also make sure the acrylic is oriented as shown in image 1 with wires coming from bottom.

    • Hold that end cap piece at its designated length and drag along the circular pieces to it. Make sure it is concentric.

    • Acrylic cement the pieces together.

  9. Clip the negative wire around 1cm away from the acrylic piece. Strip the negative wires.
    • Clip the negative wire around 1cm away from the acrylic piece.

    • Strip the negative wires.

  10. Slide on the spring terminal, with green wire through the larger hole. Thread the spring terminal all the way to the acrylic pieces, threading the negative wire through the smaller hole. Bend the wires over the glob and solder it on.
    • Slide on the spring terminal, with green wire through the larger hole.

    • Thread the spring terminal all the way to the acrylic pieces, threading the negative wire through the smaller hole.

    • Bend the wires over the glob and solder it on.

  11. Grab one of your battery tubes and put an endcap on one end with the green wire going through. Seal the end caps by cementing around the edge. If the fit is tight, you can use sandpaper to sand the inside edge of the battery tube to bevel it (just like you did for the main electronics tube).
    • Grab one of your battery tubes and put an endcap on one end with the green wire going through.

    • Seal the end caps by cementing around the edge.

    • If the fit is tight, you can use sandpaper to sand the inside edge of the battery tube to bevel it (just like you did for the main electronics tube).

    • Do the same steps for the port side battery tube.

  12. Sand one of the corners of the top of the button terminal. On the topside of the terminal, solder a glob on the corner you sanded earlier.
    • Sand one of the corners of the top of the button terminal.

    • On the topside of the terminal, solder a glob on the corner you sanded earlier.

  13. Apply two drops of super glue on opposite corners. This is important for making the potting step easier. Then place the button terminal on the front end cap.
    • Apply two drops of super glue on opposite corners. This is important for making the potting step easier.

    • Then place the button terminal on the front end cap.

  14. Next, prepare the frame and battery tubes for epoxy. Hang the battery tubes over a table edge and with your Tenda box, place the end cap on top of it as shown.
    • Next, prepare the frame and battery tubes for epoxy. Hang the battery tubes over a table edge and with your Tenda box, place the end cap on top of it as shown.

  15. Begin epoxying the end caps, make sure the epoxy flows through the entire end cap where it is slightly oozing up the wires.
    • Begin epoxying the end caps, make sure the epoxy flows through the entire end cap where it is slightly oozing up the wires.

    • When working with epoxy it is recommended that you wear gloves, safety glasses, and work in a ventilated area.

    • Allow the epoxy to cure for 4-6 hours before working with it again. Allow the epoxy to cure for 24 hours before using your OpenROV in water.

  16. Next, we'll also fill the back side of the main endcaps around the protruding parts of the syringe sections.
    • Next, we'll also fill the back side of the main endcaps around the protruding parts of the syringe sections.

    • Be careful not to allow epoxy to over-flow into the hole of the syringe as this will need to be clear for the syringe plunger (which acts as a pressure relief valve).

  17. Epoxy the other endcap at this time as well.
    • Epoxy the other endcap at this time as well.

  18. Apply epoxy to both front battery end caps till it fills the concave space of the button terminal.
    • Apply epoxy to both front battery end caps till it fills the concave space of the button terminal.

    • If the epoxy is shooting back up on you it's because there is no where for the air to escape because too much super glue was applied when gluing the terminal to the front end cap. Use a tooth pick to push the epoxy in and allow air to escape the enclosed space.

    • Allow the epoxy to cure for 4-6 hours.

  19. Continue your build by progressing to Guide 6.
    • Continue your build by progressing to Guide 6.

Finish Line

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