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Plywood cutlist

Plywood cutlist. BP. BP. 24 24 9 9 8 8 8. BP - Base Plate (Dock item#1) 4ea 23-7/8” square BR - Base Rack 4 ea 7-7/8 x 15-7/8” SR - Spotter Rack 4 ea 7-7/8 x 11-7/8” HR2 –Hinge Reinforcement Under Scoring bin : 4 ea 9 x 11-7/8”

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Plywood cutlist

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  1. Plywood cutlist BP BP 24 24 9 9 8 8 8 • BP - Base Plate (Dock item#1) • 4ea 23-7/8” square • BR - Base Rack • 4 ea 7-7/8 x 15-7/8” • SR - Spotter Rack • 4 ea 7-7/8 x 11-7/8” • HR2 –Hinge Reinforcement • Under Scoring bin : 4 ea 9 x 11-7/8” • HR3 –Midway Beam Hinge Mount : 4ea 7-7/8 x 7-7/8” • LS - Lazy Susan Cargo Turntable : 4 ea 9”x9” BP BP LS LS LS LS HR2 HR2 HR2 HR2 BR BR HR3 HR3 BR BR HR3 HR3 SR SR SR SR

  2. Plywood cutlist instructions: Starting square is (BP) 24”less kerf: about 23-7/8” After cutting the 24” squares, take care to follow the cut list and cutting instructions or everything wont fit in one sheet of plywood!

  3. 2x4 cutlist 2012-120 item 1 2012-110 item 2 2012-100 item 5 36” boat turntable arm 23-7/8” platform reinforcement (2) ~6” Tower crossmember feet (2) A 2012-130 item 2 3” tiebreaker switch 6” solar panel holders (7) standoff (1) 2012-110 item 3 6” platform feet (8) B 2012-130 item 2 3” tiebreaker switch 6” solar panel holders (5) 12” cargo bin counterweights (4) standoff (3) scrap C 3” bucket bottom backing blocks (2) 2012-140 item 3 11” stool supports (4) scrap D Note: Illustrations not to any (consistent) scale Cut 4 2x4s as shown in “A.” Cut 1 2x4 as shown in “B” and one as shown in “C” and “D.” Four remaining 2x4s are used full length for crossmember supports.

  4. Foam Sheet Cutlist a a a a a a a a a • Slice into 7-7/8” strips • Use 4 strips this way: • 1 T blank 11-7/8” • 1 T base 5-7/8” • 5 Solar panels 5-7/8” • Remaining strips can be used for spares • Or provide teams with solar panels or T’s a T blank T base Solar panel Solar panel Solar panel Solar panel Solar panel 7-7/8” 4 ea 12” 6” 6” 6” 6” 6” a Solar panel Solar panel Solar panel Solar panel Solar panel Solar panel Solar panel Solar panel 7-7/8” Spares or team parts

  5. Foam Sheet Cutlist 2 • For bottle soft caps, cut 8 sets of pieces as follows: • 1. cut a 2-3/4" diameter circle from the foamboard. • Cut a 1-1/4" diameter hole in the center of this circle, • making a doughnut. • 3. Cut a second circle 2" in diameter from the foamboard. • Apply contact cement to the inside of the hole in the • doughnut and push onto the pressurized bottle neck until it is • flush with the top of the bottle cap. • When this is dry, use contact cement to attach the second • circle to the center of the bottle/doughnut assembly, covering • the bottle cap.

  6. Instructions • A table saw cuts foam quickly/neatly/easily • But it’s a little messy, be prepared for electrostatic dust • A jigsaw with a fine tooth metal blade also works well (especially for circles) • To avoid foam surface tear-out: • Use a zero-clearance table saw insert • Or set saw to ½” depth of cut and make one pass from each side, feeding from back of the table so that saw teeth are cutting on the upswing into foam. (not yet tried) • Measure and cut one solar panel hole, then use it as a template for the remaining panels • Hole-saw cuts foam more cleanly when set to reverse direction • To avoid back surface tear-out with hole-saw on plywood &foam: • Cut only half way through from first side, then flip sides to finish hole. • This also makes it much easier to remove plug of material from saw!

  7. Notes on plywood cutsheet drawing updates • Lazy susan square needs to be > 6*sqrt2=8.5, so 9 inches will work • Spotters rack and HR2 are same size 8x12 (less 1/8” kerf)

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