Contents 25 Wire Management 26 Sticker Removal 27 Appendix A: Parts 27.1 3D Printed Parts ........66 27.2 Laser Cut Parts .
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Each step includes an estimated completion time, but the actual time may be longer if you have to learn new skills. 1.2 Parts List A complete parts list for the AutoRally platform (chassis and compute box) can be found in the AutoRally Parts List.
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1.6 Software A few software tools should be installed to complete the chassis configuration: Castle Serial Link Arduino IDE 1.7 Resources Included with Instructions AutoRally Parts List Component models for 3D printing in models/ Product manuals and datasheets in manuals/ Video tutorials saved for offline viewing in...
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3 FABRICATION 2 3D Printing Time 30 hours 27 minutes (print time) Parts Models for all chassis components are .stl files located in models/ Instructions a. Print all custom chassis components: i. Electronics box ii. Electronics box lid iii. GPS box iv.
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4 LASER CUTTING Down 90 R3.00 Up 90 R3.00 DRAWN aminer33 7/14/2018 CHECKED TITLE APPROVED SIZE DWG NO SCALE 4 : 1 SHEET 4 Laser Cutting Time 0 hours 30 minutes Parts Models for all chassis components are .stl files located in models/ 5 64 acrylic sheet Copper foil sheet 11 5...
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4 LASER CUTTING 6mm thick Craft Foam Notes If available, use a laser cutter to cut out the parts. Otherwise, print the provided PDFs onto paper and use as stencils to cut the part manually. Instructions a. GPS box lid i.
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5 CAPACITOR PRECHARGE CIRCUIT b. Battery foam i. Using the provided Chassis Battery Foam.pdf file, cut out 2 copies of the battery foam. ii. Hot glue the 2 battery foam cutouts together. 5 Capacitor Precharge Circuit Time 4 hours 0 minutes Parts Castle Creations Mamba XL-X ESC 1 chassis battery (6500 or 9000 mAh)
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5 CAPACITOR PRECHARGE CIRCUIT 1 resistor, 2 ohm, 3W 2 6.5mm male CC Bullet 1 piece red shrink wrap for 6.5mm bullet 1 piece black shrink wrap for 6.5mm bullet red wire, 16awg assorted shrink wrap Caution: When working with batteries, always keep one exposed contact covered to avoid short circuits.
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5 CAPACITOR PRECHARGE CIRCUIT f. Solder the unbent lead of the resistor to female 4mm connector wire and heat shrink the con- nection. g. Remove the heat shrink from the red battery bullet connector. Cut away a small portion of insulation on one side of the red battery lead close to the bullet connectors and on one side of the red ESC power wire.It may help to tin the exposed wire to help with the upcoming soldering.
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5 CAPACITOR PRECHARGE CIRCUIT j. Use liquid electrical tape to cover the exposed connections on the ESC as seen in the images below. k. Loop a length of red 16 awg wire and solder both ends into the solder cup of a male banana connector.
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6 ELECTRIC CONVERSION 6 Electric Conversion Time 8 hours 0 minutes Parts Castle Creations ESC Castle Creations 2028 motor Castle Creations motor fan Castle Creations Baja (CCB) conversion hardware or Rovan Baja (RB) conversion hardware If using RB kit: – 2 M5 16mm button head screws –...
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6 ELECTRIC CONVERSION i. Removal of rear skid plate: Remove the single body clip at the back holding the skid plate to the frame. Then pull the skid plate out. ii. Removal of side guard rails: For each guard rail, remove the 2 screws on the top (front side), 2 at the bottom (rear side) and 1 body clip each (rear side).
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6 ELECTRIC CONVERSION c. Remove the rear brake and clutch, both engine mount braces, the air filter sleeve set, and all engine screws on the base plate (on the bottom of the chassis) as shown in video #2. d. Disconnect the throttle linkage, and remove the engine as shown in video #2.
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6 ELECTRIC CONVERSION e. Disconnect the fuel lines and remove the gas tank as shown in video #2. Reserve the plastic supports that connect the tank to the aluminum chassis for the Electronics Box installation. f. Disconnect the steering servo and remove the battery box as shown in video #2. g.
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6 ELECTRIC CONVERSION h. At about the two minute mark in video #3, you will be using a diff spacer (item #18), a spacer with a flat on one side. The CCB kit includes this spacer, but the RB kit only includes round spacers.
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6 ELECTRIC CONVERSION k. The motor mount plate in the CCB kit has three slots for mounting, while the RB kit has only two slots. Both kits use M4 8mm screws for mounting. Follow the details of the next two steps exactly as written.
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6 ELECTRIC CONVERSION Then, loosely install the two M5 15mm flat head screws (item #22) into the passenger frame plate. Finally, tighten all the screws on the passenger frame plate first, and then tighten the screws for the roll cage. m.
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6 ELECTRIC CONVERSION p. This step only applies if you are using the RB kit. In video #6, the ESC is installed. The diff plate (item #8) in the RB kit has two screw holes that are not aligned with the slots on the ESC.
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7 STEERING LINKAGE AND SIDE RAIL GUARDS 7 Steering Linkage and Side Rail Guards Time 1 hours 0 minutes Parts Turtle Racing Billet Servo Saver Integy Side Rail Guards (if available) Low-temperature threadlock Instructions a. Complete through step 13 of the Steering Linkage Instruction Booklet, also located in manuals/...
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8 BATTERY BOX ELIMINATOR AND STEERING SERVO b. Mount the side rail guards, and add a drop of threadlock on each of the four mounting screws. If available, use the Integy side rail guards instead of the stock plastic side rail guards. 8 Battery Box Eliminator and Steering Servo Time 1 hours 0 minutes Parts...
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9 SHOCKS ii. Position the servo horn such that the arm is vertical when the servo is centered. To find the vertical position, first move the horn to either extreme. The rightmost photo below shows the position of the servo horn when the servo is centered. iii.
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10 AXLE EXTENDERS c. Refer to the Shock Assembly section in the Instruction Manual to replace the HD Piston 16mm C-1 (16 holes) with HD Piston 16mm A-1 (2 holes). This is required to be done before filling the shocks with oil. d.
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10 AXLE EXTENDERS ii. Remove the top and bottom screws that hold the front axles boots to the rest of the axle assembly. iii. Remove the stock axle extenders and replace with the Darksouls front axle extenders. iv. Secure the front axle extenders using C-clips.
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10 AXLE EXTENDERS v. Replace the screws that connect the axle boots to the rest of the axle assembly. b. Rear axle extenders i. Remove the screws from inside the rear axle extenders. ii. Push out the pins that hold the rear axle extenders to the drive shaft. iii.
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11 WHEEL ROTATION SENSOR MAGNET MOUNTS iv. Replace the pins. v. Loosely screw in the nuts on the rear axle extenders so that they do not get misplaced. 11 Wheel Rotation Sensor Magnet Mounts Time 1 hours 15 minutes Parts 2 3D printed front wheel magnet mounts (if front brakes are not used) 2 3D printed rear wheel magnet mounts 4x12 wheel rotation sensor magnets...
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11 WHEEL ROTATION SENSOR MAGNET MOUNTS b. Take one of the magnets and bring it near the front face of the Hall-effect sensor of the test circuit assembled in the previous step. The front face has writing on it. If the LED does not light up, flip the magnet over and try again.
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12 FRONT AND REAR ROTATION SENSORS 12 Front and Rear Rotation Sensors Time 1 hours 30 minutes Parts 6 Optek Hallogic OH090U Hall Effect Sensors 6 Futaba J female connector assemblies 6 11” lengths of servo wire Heat shrink Zip ties Instructions a.
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12 FRONT AND REAR ROTATION SENSORS e. Test each of the completed rotation sensor assemblies using the test circuit and the wheel rotation magnet mounts created in previous steps. f. Install the 3D printed rear rotation sensor mounts as shown in the photo. Note that the lock nut should be installed with the protrusion facing downward as shown in the photo.
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13 FRONT BRAKES, DISC ALIGNER i. Only complete this step if you are installing front wheel rotation sensor magnet mounts and not using front brakes. Use hot glue to secure one of the sensor assemblies to each of the front hubs. Carefully align the sensor with the magnets on the front rotation sensor magnet mount/brake disc in order to ensure that the sensor will reliably detect each magnet as it passes the sensor face.
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13 FRONT BRAKES, DISC ALIGNER 2 M3 50mm screws 2 M4 6mm screws (can use M4x14 from above and just pad with washers if needed) 4 M4 14mm screws (same as for the motherboard in the compute box) 4 M4 nuts M4 washers Throttle pivot set Brake rod set...
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13 FRONT BRAKES, DISC ALIGNER d. Verify that the magents are aligned with the sensors hot glued to the hub and that the magenets clear the calipers when spinning. Adjust the sensor locations if required. e. Attach the master cylinder to the aluminum master cylinder plate using 2 M4 6mm screws and, if necessary, use M4 washers to keep the screws from bottoming out.
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13 FRONT BRAKES, DISC ALIGNER k. Make a 10 inch servo extension cable with the Futaba J connector assembly. l. Follow the normal instructions for connecting brake lines and bleeding. The brake lines should not be rubbing against the tires or any moving component of the vehicle, but the lines should still have enough slack to allow the wheel to steer from side to side.
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14 TIRE FOAMS m. Secure the brake line with a few zip ties to the chassis so they do not snag on chassis parts when the steering actuates and install a bleed valve cap on the brake caliper and master cylindar bleed valves once done bleeding.
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15 CUT ROLL CAGE i. Ensure that the rubber tire material is properly seated into the respective slots. Then ensure that the rims slots properly align with the tire material. ii. This step may require more than one person. f. Make sure the beadlocks sit flat and do not pucker when the screws are installed. If there is puckering, loosen the screws, realign the tire rubber and then retighten.
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15 CUT ROLL CAGE b. Remove all roll cage components forward of the cut. The remaining components are shown below. c. Secure remaining cut ends to shock tower with large zip ties d. Cut center roll bar off just above side rail guards. Discard the part of the roll cage shown below.
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16 RC TRANSMITTER 16 RC Transmitter Time 0 hours 30 minutes Parts Futaba 4PLS transmitter Futaba receiver Instructions a. Refer to the included Futaba 4PLS manual or the PDF file in the folder to locate and manuals/ set the specified parameters. b.
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17 ESC e. On the transmitter, configure PS1 to operate Channel 3 (CH3). f. On the transmitter, configure PS2 to operate Channel 4 (CH4). g. On the transmitter, configure the PS2 mode to ALT (alternate). 17 ESC Time 0 hours 20 minutes Parts Castle Serial Link software installed from Castle Serial Link...
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19 PROTOSHIELD ASSEMBLY i. Basic BEC Voltage to 7.5 V. ii. Basic Auto-Lipo Volts/Cell to 3.1V. iii. Power Start Power to High. iv. Advanced Throttle Dead Band to 0.0625 ms. v. Advanced Link Live Enable to Enabled. vi. Logging Sample Frequency to Disabled c.
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The following diagram shows the schematic for the components within and connected to the Elec- tronics Box. This schematic defines the connections we will be making on the ProtoShield. NOTE: A scalable version of the drawings (AutoRally Electronics Box) is available in the folder wiringDiagrams/.
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19 PROTOSHIELD ASSEMBLY Instructions a. Assemble the base protoshield kit, including its various headers, buttons, and jumpers. b. Make sure the voltage selection jumper on the ProtoShield is set to 3.3V. c. Cut two 1” lengths of blue wire and one 1/4” length of uninsulated wire (or scrap leads cut from capacitors or resistors).
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19 PROTOSHIELD ASSEMBLY g. Cut two short lengths, one about 1 1/2” and one about 2” of red wire. Solder one end of each wire to the 5V output pin of the arduino footprint. Solder the other end of the 1 1/2” length wire to via M9.
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19 PROTOSHIELD ASSEMBLY j. Cut four lengths of Yellow-Red-Black servo cable. Two of length 13” and two of length 22”. These will be used for the wheel rotation sensors. Also, cut one 1/2” length of black wire. Solder the black wires of all of the servo cables to pads K1 through N1. The order is not important.
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19 PROTOSHIELD ASSEMBLY p. Cut a 6” length of blue wire. Crimp one end into a single-position, female 0.1” header. Solder the other end to via J13. q. Cut two 6” lengths of Green-Blue-Purple servo cable. Crimp one end of each cable into the same three-position, female 0.1”...
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19 PROTOSHIELD ASSEMBLY t. Cut a 6” length of Yellow-Red-Black servo cable. Remove the Yellow wire to create a single Red and Black servo cable. Crimp and insert one end of each servo wire into a two-position, female 0.1” header. Solder the other end to pads J19 (Red) and H21 (Black). u.
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19 PROTOSHIELD ASSEMBLY v. On the bottom of the ProtoShield, use excess solder to connect the following sets of pads. Be careful not to accidentally short neighbooring pads with the extra solder. i. I19, J19, and K19 ii. I18 and J18 iii.
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20 ELECTRONICS BOX ASSEMBLY y. Solder a 2 inch black wire A12 to H21. On the underside of the protoshield. Connect A12 to A13 with solder. 20 Electronics Box Assembly Time 2 hours 0 minutes Parts Arduino DUE Assembled ProtoShield from previous step Castle Creations Serial Link Pololu RC Relay Pololu Servo Multiplexer...
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20 ELECTRONICS BOX ASSEMBLY NOTE: A scalable version of the drawings (AutoRally Electronics Box) is available in the folder wiringDiagrams/. Instructions a. Upload code to Due and verify it is sending data using a serial monitor (data values should be garbage right now).
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20 ELECTRONICS BOX ASSEMBLY capacitor, and plug this into output channel 2 (OUT2) on the Pololu Servo Multiplexer. If you do not have the Racers Edge capacitor, insert this end into a single-position, 0.1” header and plug this into output channel 2 (OUT2) on the Pololu Servo Multiplexer. n.
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21 ELECTRONICS BOX INSTALLATION 21 Electronics Box Installation Time 1 hours 30 minutes Parts Printed electronics box Electronics box assembly from previous step 4 completed wheel rotation sensor assemblies 2 reserved plastic supports (Baja part number 85420-6) reserved from fuel tank removal 3 M3 nylon washers 4 M3 hex nuts 1 M3 6 mm screw...
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21 ELECTRONICS BOX INSTALLATION b. Install the M3 6 mm screw and an M3 nut in the hole at the bottom of the electronics box with the head of the screw on the bottom of the electronics box. Place electronics box assembly in chassis with the mounting holes pressed over the plastic supports on the chassis.
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21 ELECTRONICS BOX INSTALLATION f. Replace the 3 1 female housings of the motor shroud fan and the ESC fan cables with with 2 1 female housings. g. Plug the motor shroud fan wires and ESC fan wire into the connections specified in the schematic. h.
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21 ELECTRONICS BOX INSTALLATION j. Cut the USB cable down to a 2’ length. k. Solder the 4 wires into the appropriate pin slots of the USB breakout board as shown in the images below.
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21 ELECTRONICS BOX INSTALLATION l. Secure the USB wire to the wall of the electronics box using a zip tip saddle and two zip ties as shown in the images below. Note the position of the zip-tie saddle in between the castle serial link and the receiver.
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21 ELECTRONICS BOX INSTALLATION o. Use pliers to flatten the solder tips of the button of the protoboard. p. Clip-off two of the nylon washers as shown in the images as they do not sit flat on the Arduino. q. Attach the Arduino Due to the electronics box using 3 M3x40 mm screws, 3 M3 nylon washers, 3 M3x18 mm nylon spacers to the 3 nuts epoxied in Step 1;...
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21 ELECTRONICS BOX INSTALLATION r. Plug the USB breakout board into the programming port of the Arduino Due. s. Hot glue the rear bumpers (Baja part number 85420-6) to the underside of the chassis to ensure that they do not fall off when the body clips are secured. t.
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22 TEST ELECTRONICS BOX 22 Test Electronics Box Time 1 hours 0 minutes Refer to the Operating Procedures document to power the chassis, for the ESC power sequence, and transmitter usage. Instructions a. Calibrate ESC by following the How to Calibrate the ESC in the Castle Creations Mambla XL X Driver’s Ed Guide.
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23 GPS BOX ASSEMBLY i. Castle Serial Link data is being transmitted (battery voltage, motor speed, ...). ii. Spin each axle to verify the wheel rotation sensors are mounted properly and plugged into the correct spot. iii. Manual and autonomous mode are correctly detected. iv.
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23 GPS BOX ASSEMBLY b. Cut the 20-pin ribbon cable down to 4”. c. Strip approximately 1.5” insulation off one end of the 15” piece of GPS cable. d. Referring to the wiring diagram above, solder all through-wires from the ribbon cable to the GPS cable.
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23 GPS BOX ASSEMBLY e. Referring to the diagram above, solder one end of the resistor to the white wire in the GPS cable. Solder the ribbon cable corresponding to the white wire to this junction. Solder all of the ground wires from the ribbon cable together. Remember to slip a small piece of heat shrink over the ribbon cable wire before soldering.
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23 GPS BOX ASSEMBLY wires in the GPS cable, and tin the leads on the other end. Remember to slide a small piece of heat shrink over the wires before soldering. j. Use a heat gun to heat all heat shrink ensuring that it covers all exposed wire and solder. k.
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23 GPS BOX ASSEMBLY n. Push the GPS cable through the bushing so the ribbon cable and voltage regulator are inside the box. Connect the ribbon cable to the GPS unit. The colored wire should be connected to the pin labeled with the small diamond mark on the GPS unit. Connect the antenna to the GPS unit.
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24 GPS BOX INSTALLATION p. Attach the antenna to the lid and screw the lid into place using 4 M3 8 screws and 4 M3 nuts. Put a dab of hot glue onto the nuts to hold them in place. q.
25 WIRE MANAGEMENT a. Mount the GPS box to the rear body mount area of the chassis (part 85417-3: see photo for exact placement) using 4 M4 20 mm screws. 25 Wire Management Time 0 hours 20 minutes Parts 0.5” outer diameter split loom Small zip ties Electronics box lid 4 small body clips...
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25 WIRE MANAGEMENT d. Attach zip ties on each end of the split loom to hold the wires in place. e. Zip tie the split loom to the chassis near the electronics box using the hole that exists in the chassis, the engine mount brace above the side rail guards, and the hole in the back plate under the ESC.
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25 WIRE MANAGEMENT g. Hot glue Futaba J male housing of the wheel rotation sensor wires to the shock towers of the chassis. h. Loop the front wheel rotation sensor wires around the front supports in order to reduce slack to the minimum required to route these wires, if needed.
26 STICKER REMOVAL k. Connect the engine guards to the under guard using body clips. Then, install the under guard and secure it with a body clip at the rear of the chassis. See below for pictures. 26 Sticker Removal Time 0 hours 30 minutes Parts Baja 5SC body...
27 APPENDIX A: PARTS 27 Appendix A: Parts 27.1 3D Printed Parts Electronics box Electronics box lid GPS box Front brake aligners Rear wheel rotation sensor mounts...
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27 APPENDIX A: PARTS Castle Creations 2028 electric motor Castle Creations motor fan Conversion hardware kit. Either Castle Creations Baja conversion hardware (left) or Rovan Baja conversion hardware (right).
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27 APPENDIX A: PARTS Turtle Racing Billet Servo Saver Integy side rail guards Team Fast Eddy Battery Box Eliminator Kit...
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27 APPENDIX A: PARTS Savox SV-0235MG steering servo (left) and SV-1271TG brake servo (right) Shock springs, front, rear long, rear short Shock Fluid, Factory Team 60w, 59 ml Darksouls Baja Axle Extender Set...
27 APPENDIX A: PARTS Mecatech front brake kit for Baja Zero-growth tire foams Figure 2: Red front tire (left) and Blue back tire (right) 27.5 Electronic Components 9000 mAh 4S 14.8v Chassis Battery Pair...
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27 APPENDIX A: PARTS 1900 mAh 2S LiFe 6.6V Transmitter Battery Arduino DUE Adafruit ProtoShield for DUE Baja Series Adapter...
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27 APPENDIX A: PARTS Castle Serial Link Castle Link Programmer CUI 3.3V 2.4A Voltage Regulator PYB10-Q24-S3-T Futaba 4PV Transmitter with R304SB Receiver...
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27 APPENDIX A: PARTS Futaba FUTM1725 Charger for Futaba 4PV Glitch Capacitor GPS antenna...
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27 APPENDIX A: PARTS GPS antenna cable GPS box fan Hallogic OH090U Hall-Effect sensors...
29 APPENDIX C: CONTRIBUTORS April 2016 KS, MP, BG, created MB, SS, JM July 2016 KS, MP, BG, updated electronics box instructions, updated MB, SS, JM images, cleaned up document September 2016 BG, MB Fixed error in GPS breakout cable in compute box diagram, spelling fixes February 2017 Moved GPS power supplies into GPS box, re-...
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