# K2Aley GAR-BOT Assembly Instructions
Copyright (c) 2026 K2Aley. GAR-BOT. All rights reserved.

Use this with `GAR-BOT_USER_MANUAL.html`, `GAR-BOT_CONNECTIONS.md`,
`GAR-BOT_PRINT_QUEUE.md`, and `docs/GAR-BOT_PART_ACCURACY_REPORT.md`.

## Build Order

1. Print and inspect all frame parts.
2. Install M3 heat-set inserts before bolting parts together.
3. Build the frame rectangle.
4. Install motors, motor drivers, power covers, and cable clips.
5. Install and seal the Raspberry Pi 5 electronics bay.
6. Install the 7 inch touchscreen frame.
7. Mount both front claws to the forward shoulder bridge.
8. Assemble the RP Zero 2 W + Pico Voice remote transmitter.
9. Install K2Aley / GAR-BOT badges and warning labels.
10. Complete wiring, water-resistance checks, and first power-on tests.

## Numbered Part Groups

| Stage | Part numbers | Parts |
| --- | --- | --- |
| Frame | 8-15 | side rails, crossmembers, skid plate, battery tray, deck, claw bridge |
| Drive and power | 3, 4, 6, 19-22 | motor drivers, buck converter, motors, covers, cable clips |
| Sealed electronics | 5, 16-18, 42 | RP5 stack, electronics bay, gasketed lid, gland panel, LoRa guard |
| Touchscreen | 23-27 | bezel, rain hood, uprights, top bar |
| Claws | 1, 2, 28-38 | claw reference, servo board, bases, pivots, palms, fingers, links, covers |
| Remote | 7, 39-41 | RP Zero 2 W + Pico Voice, case front/back, LoRa bulkhead |
| Branding | 43-45 | lid badge, side badge, water warning badge |

## 1. Frame Assembly

Parts: `8 9 10 11 12 13 14 15`

- Dry-fit left and right side rails.
- Bolt front and rear crossmembers to the rails.
- Fit the bottom skid plate under the frame.
- Fit the center battery tray inside the frame.
- Fit the electronics deck plate above the tray.
- Bolt the front claw bridge to the forward frame/shoulder area.
- Confirm the frame is square before tightening everything.

## 2. Drive and Power Assembly

Parts: `3 4 6 19 20 21 22`

- Mount four 24V gear motors at the wheel corners so each motor direct-drives
  its own wheel.
- Use one IBT-2 motor driver per motor.
- Do not install chain, sprockets, or exposed belt reductions in the active
  water-resistant build.
- Install IBT-2 driver covers after wiring inspection.
- Mount the 24V-to-5V buck converter and cover.
- Install motor splash shields.
- Route motor wires through drip-loop clips before entering sealed areas.

## 3. Sealed Electronics Assembly

Parts: `5 16 17 18 42`

- Place the Raspberry Pi 5 and relay HAT in the electronics bay.
- Keep Pico Voice on the RP5 40-pin header, not on USB.
- Route external wires through the cable gland panel.
- Install the LoRa antenna guard/bulkhead as needed.
- Fit gasket material and close the gasketed lid.

## 4. Touchscreen Assembly

Parts: `23 24 25 26 27`

- Bolt left and right touchscreen uprights to the deck.
- Install the top tie bar.
- Seat the 7 inch USB touchscreen in the bezel.
- Fit the rain hood.
- Route touchscreen cable with strain relief and drip loop.

## 5. Two-Claw Assembly

Parts: `1 2 28 29 30 31 32 33 34 35 36 37 38`

- Mount left and right claw base mounts to the front shoulder bridge.
- Install round shoulder pivots.
- Add sealed servo pockets and wrist servo cradles.
- Install palms, fingers, and link bars.
- Fit gear guards and forearm wire covers.
- Place one claw controller board per claw and cover it.
- Confirm left and right claws mirror each other.

## 6. Remote Transmitter Assembly

Parts: `7 39 40 41`

- Place RP Zero 2 W and Pico Voice into the remote case.
- Mount LoRa antenna bulkhead through the case wall.
- Close front and back case parts after boot and radio checks.
- Arduino Pro Mini is not used in the active transmitter design.

## 7. Wiring Checks

- Fuse the 24V bus close to the battery.
- E-stop must interrupt the switched 24V load bus.
- Measure buck converter output before connecting the Raspberry Pi 5.
- Keep servo power separate from Raspberry Pi power.
- Tie logic grounds to one common ground point.
- RP5 USB plan: left claw, right claw, touchscreen, LoRa/radio USB bridge or hub.
- Pico Voice uses the RP5 40-pin header.

## 8. Water-Resistance Checks

- No exposed Pi, relay HAT, motor driver, buck converter, radio PCB, USB hub,
  claw controller, or loose terminal block during wet use.
- Use gaskets, cable glands, bulkheads, drip loops, and covered wire channels.
- Paper towel test:
  1. Power off.
  2. Place dry paper towel strips inside sealed bays.
  3. Mist outside lightly for 30 seconds.
  4. Wait 10 minutes.
  5. Open and inspect.
  6. Fix leaks before powered testing.

## 9. First Power-On

1. Lift GAR-BOT so wheels and claws cannot hit anything.
2. Confirm 5.1V before powering the Raspberry Pi 5.
3. Boot RP5 and verify touchscreen.
4. Verify both claw controllers appear.
5. Enable motor power with e-stop reachable.
6. Jog one motor at a time at low speed.
7. Move each claw slowly and watch for binding.
8. Test LoRa/remote commands before driving on the ground.

## Final PASS

- Frame is square.
- All covers and lids are installed.
- All glands and drip loops are in place.
- Wheels spin correctly.
- Claws move correctly.
- RP5, touchscreen, remote, and LoRa pass bench checks.
- Water-resistance paper towel test passes.
