Check the video here:
Step 1: Insert the screws through one thigh
Since I use the round-head M3 screws (5.5mm head), it sinks through the hole on the thigh plate. So I use two washers.
Tips: Here I use some acrylic washers. If you don't have these, you can make them with a thick cardboard or cuttable plastic board . Then cut the board based on the holes' size on the thigh and the keys.
Step 2: Put a key on one screw and a wash on the other
It doesn't matter whether to put which on which. But remember the washer should be almost as thick as the key.
Step 3: Put more keys in the same way
Place a key and a washer alternately into both screws.
Note: When placing the key, pay attention to the hole on the key and the washer's size.
Tips: Keys into one screw should be nearly as thick as those into the other, which would make it most convenient to rotate out the keys on two sides.
Step 4: Place the other thigh plate onside
After putting the thigh, fix them with two M3 nuts. Remember to screw a little first, and arrange the keys and washers well - one key on a screw, one washer on the other in a same level.
Good job to myself!
P.S. : How to make these two cover boards if I don't have the SunFounder robot's thigh?
Prepare a hard and thick board - better use wood, plastic, polystyrene (EPS) board, or other materials than paper in case of getting wet and soft. Or if you have access to a 3D-printer, you make design and make one. If you really need to use paper cardboards, find one with water-proof film.
I've uploaded a file for this thigh plate and you can download the photo to draw/print your own.
1. I just happen to have a disused box and I've printed the thigh plate on a piece of paper (plate in actual size: 73*21mm).
2. Cut the plate's shape out and press it on the box board.
3. Draw along the outline and cut it out.
4. Pay attention to the holes at two ends - you can drill or punch a hole with a drill or knife or just a screwdriver, and the diameter would depend on the screw size you use.
P.S. : How to cut the cardboard for washer?
Put the key onto the card, mark the edge with pencil. Cut the washer out based on the mark. Drill/Cut a hole in the middle, diameter a little larger than the screw size 3mm.
Cut more for sufficient thickness.
P.P.S.: Thanks for our customer Seth C who had uploaded his works http://imgur.com/xHbfE2E on our Forum. Thus we are inspired to make this project for all of you. Enjoy!