Three crews.
One working robot.

Gather: HD Hex motors, UltraPlanetary cartridges, motor plates, outputs, and mounting brackets

1. Follow pages 10–17 for the two 20:1 drive motor/gearbox groups and the 1:1 launcher group. Keep the groups labeled.
2. Check the cartridge order, output orientation, mounting bracket, and fastener lengths against each diagram. A mentor reviews any threadlocker use and tightening.

Pause & explain: Are both drive outputs assembled alike, with the launcher motor clearly separate?

Gather: 90 mm 5 mm hex shafts, omni wheels, bearings, spacers, shaft collars, 10-tooth sprockets

1. Use pages 18–34 to make two drive shafts, two single-sprocket shafts, and two double-sprocket shafts. Keep the bearing, spacer, and sprocket order shown for each type.
2. Some drive-shaft parts are used temporarily to establish spacing and reinstalled later. Keep them with the same shaft in a labeled tray.

Pause & explain: Do both left and right sets spin freely and retain the intended spacing?

Gather: #25 chain and the kit chain tool

1. Read the chain-tool sequence on pages 35–39 with a mentor. The guide calls for one 54-link intake loop and four 56-link drive loops on page 40.
2. Count the links before closing each loop. Avoid pushing a pin all the way out unless you have the correct master-link plan.

Pause & explain: Are the one short loop and four drive loops separately labeled and free of twisted links?

Gather: 20:1 drive motor group, 408 mm C channel, endcap, 120 mm extrusion, lap brackets, four 40 mm standoffs

1. Fasten the gearbox output at the fourth hole from the end of the C channel, using the diagram on page 52 for orientation. Add the endcap and the small upright extrusion.
2. Place the lap brackets and four standoffs as shown through page 58. Leave the brackets that must accept later cross pieces adjustable.

Pause & explain: Does the motor output line up with the future drive shaft, without binding?

Gather: Drive shaft, single and double sprocket shafts, two 56-link chains, collars, tensioning bushings

1. Loop the two chains around the three matching sprockets and place the drive shaft into the motor output. Route each loop around its standoffs as shown.
2. Retain the other shafts with collars, add the tensioning bushings, and close the rail with the second 408 mm C channel. Turn the system by hand with power disconnected.

Pause & explain: Do both chains stay on their sprockets without rubbing the channel?

Gather: Second 20:1 drive motor, C channels, remaining drive shafts, two 56-link chains, standoffs, collars

1. Build the opposite rail from pages 64–73. Mirror its orientation; do not assume that the motor and bracket directions are identical to the first rail.
2. Check the chain path and hand rotation before tightening the adjustable brackets.

Pause & explain: Do the two rails form a left/right pair with the same free motion?

Gather: Completed pusher from assembly 02 and its servo bracket

1. Slide the servo bracket onto the indicated second drive rail before closing the full base. The guide places its arm next to the endcap.
2. With power isolated, move the arm through its intended path and adjust the bracket if the arm catches on the extrusion.

Pause & explain: Can the arm travel without striking the rail, wheel, or a cable?

Gather: 248 mm C channels and extrusion crossmembers, corner brackets, both completed rails

1. Add the 248 mm cross pieces as shown on pages 76–82. Bring the rails together and align the brackets before final tightening.
2. Stand the open rail ends on a flat surface or check with a square. Fix any twist now; a skewed base will affect wheel contact and straight-line driving.

Pause & explain: Are both rails parallel and the frame square?

Gather: Battery holder, hook-and-loop restraint, Control Hub, 16 mm mounting screws, switch bracket

1. Mount the battery holder between the rails, make a secure removable battery restraint, then take the battery back out during the rest of assembly.
2. Attach the Control Hub and the two 420 mm cross extrusions as shown on pages 78–83. Put the switch where a driver or mentor can reach it quickly.

Pause & explain: Can the battery be removed, wires be routed safely, and the main switch still be reached?

Gather: Omni, grip, and traction wheels, through-bore bearings, collars, four 70 mm mounting extrusions

1. Fit the omni wheel on each drive shaft and the grip and traction wheels on the remaining shafts using the bearing and collar order on pages 83–84.
2. Add the four upright mounting pieces from pages 84–86. These will support later assemblies, so compare their orientation to REV’s pictures.

Pause & explain: Do all wheels turn freely, and are the upright mounts positioned as matched pairs?