Center the top deck as perfectly as possible, but never let
the fan holes get out of alignment. It’s more critical that
the fan holes line up properly than the decks.
It’s best to cut out and drill the holes in both the top
and bottom decks before moving on to complete the
bottom deck. That way, the holes in both decks align with
each other. So, begin by cutting two pieces of 5/32 inch
thick Correplast to the shapes and sizes illustrated below. A
utility knife and metal straight edge work best for this. Use
a T-square to lay out the lines and ensure the HoverBot
remains square. Don’t worry about the center or four
corner holes at this time. Just mark their location.
You can locate the center of each deck by drawing
diagonal lines from the corners. Alternatively, you could use
a ruler and measure to the center. After marking the center
of each deck, use a T-square to draw right angle lines that
intersect the center of each deck. Place a 1-3/4 inch circle
template at the center point of each deck and draw the
circle on the Correplast. This hole marks where the fan will
blow air to lift the HoverBot. Use a small-bladed Exacto™
knife and carefully cut out the fan holes. Next, stack the
top deck on the bottom deck and align the fan holes. The
Here are the dimensions for my HoverBot’s bottom deck.
You can make yours larger or smaller. However, a larger
HoverBot may not lift as well.
Note that the top deck is not as wide as the bottom deck.
stacked decks should look like this.
There are four holes in the corners of the decks for the
riser bolts. These holes must line up if the lift fan is to sit
vertically in the HoverBot. Therefore, after aligning the top
and bottom decks use several pieces of masking tape to
keep them aligned while you drill the riser holes. I find a
Dremel is the easiest way to make these holes.
The risers are #6-32 bolts, so a 1/8 inch drill bit will
suffice to make these holes. The exact positions of the riser
holes are not critical, but keep them at least 1-1/2 inches
from the edge of the bottom deck. After drilling the first
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