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2019-2020 FIRST ® Tech Challenge

Basic ‘Bot Guide for REV

Part 1
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Sponsor Thank You

Thank you to our generous sponsors for your continued support of the FIRST® Tech Challenge!

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Revision History
Revision Date Description
1 5/30/2019 First Revision
1.2 7/02/2019 Initial release

Contents
Contents ............................................................................................................................................................ 3
Introduction........................................................................................................................................................ 5
What is FIRST® Tech Challenge? .................................................................................................................. 5
FIRST Core Values ........................................................................................................................................ 5
Gracious Professionalism® ................................................................................................................................ 5
Introduction to the Guide ................................................................................................................................... 6
Introduction .................................................................................................................................................... 6
Parts .............................................................................................................................................................. 6
Tips and Tricks............................................................................................................................................... 6
Construction ...................................................................................................................................................... 7
Drive Assemblies and Frame ......................................................................................................................... 7
Step 1: Build Drive Brackets ....................................................................................................................... 7
Step 2: Build Motor Assemblies .................................................................................................................. 8
Step 3: Build the Right and Left Rail ........................................................................................................... 9
Step 4: Add Drive Wheels......................................................................................................................... 10
Back Support Beam ..................................................................................................................................... 11
Step 1: Add Screws to Corner Brackets.................................................................................................... 11
Step 2: Add Corner Brackets to Beam ...................................................................................................... 12
Step 3: Add Floating Screws to Beam ...................................................................................................... 13
Step 4: Add Back Support Beam .............................................................................................................. 14
Front Support Beam ..................................................................................................................................... 15
Step 1: Add Screws to Corner Brackets.................................................................................................... 15
Step 2: Add Corner Brackets to Beam ...................................................................................................... 16
Step 3: Add Floating Screws to Beam ...................................................................................................... 17
Step 4: Add Front Support Beam .............................................................................................................. 18
Step 5: Add Switch Bracket ...................................................................................................................... 19
Caster Wheels ............................................................................................................................................. 20
Step 1: Build Caster Brackets ................................................................................................................... 20
Step 2: Add Caster Brackets to Chassis ................................................................................................... 21
Step 2: Add the Omni Wheels................................................................................................................... 22
Motor and Sensor Controller ........................................................................................................................ 25
Step 1: Add the Support Plate .................................................................................................................. 25

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Step 2: Add the Rev Robotics Expansion Hub .......................................................................................... 26

Step 3: Add the Expansion Hub to Phone Cable ...................................................................................... 27
Step 4: Add the Left Drive Motor Power Cable ......................................................................................... 28
Step 5: Add the Right Drive Motor Power Cable ....................................................................................... 29
Robot Controller ........................................................................................................................................... 30
Step 1: Add the Phone Support Plate ....................................................................................................... 30
Step 2: Add the Robot Controller Cell Phone to the Holder....................................................................... 31
Step 3: Connect the Robot Controller to the Expansion Hub (Part 1) ........................................................ 32
Step 4: Connect the Robot Controller to the Expansion Hub (Part 2) ........................................................ 33
Power Switch ............................................................................................................................................... 34
Step 1: Add the Switch ............................................................................................................................. 34
Step 2: Connect the Switch to the Motor and Sensor Controller ............................................................... 35
Battery ......................................................................................................................................................... 36
Step 1: Add the Battery ............................................................................................................................ 36
Step 2: Connect the Battery to the Switch ................................................................................................ 37
Final Steps ...................................................................................................................................................... 38
Special Thanks and Best Wishes .................................................................................................................... 38
Appendix A – Resources ................................................................................................................................. 39
Game Forum Q&A ....................................................................................................................................... 39
FIRST Tech Challenge Game Manuals ........................................................................................................ 39
FIRST Headquarters Pre-Event Support ...................................................................................................... 39
FIRST Websites ........................................................................................................................................... 39
FIRST Tech Challenge Social Media ........................................................................................................... 39
Feedback ..................................................................................................................................................... 39

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Introduction

What is FIRST® Tech Challenge?

FIRST® Tech Challenge is a student-centered program that focuses on giving students a unique and
stimulating experience. Each year, teams engage in a new game where they design, build, test, and program
autonomous and driver operated robots that must perform a series of tasks. To learn more about FIRST® Tech
Challenge and other FIRST® Programs, visit www.firstinspires.org.

FIRST Core Values

We express the FIRST® philosophies of Gracious Professionalism® and Coopertition® through our Core
Values:

• Discovery: We explore new skills and ideas.

• Innovation: We use creativity and persistence to solve problems.
• Impact: We apply what we learn to improve our world.
• Inclusion: We respect each other and embrace our differences.
• Teamwork: We are stronger when we work together.
• Fun: We enjoy and celebrate what we do!

Gracious Professionalism®

FIRST® uses this term to describe our programs’ intent.

Gracious Professionalism® is a way of doing things that encourages high-quality work, emphasizes the
value of others, and respects individuals and the community.

Watch Dr. Woodie Flowers explain Gracious Professionalism in this short video.

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Introduction to the Guide

Introduction
The Basic ‘Bot Guide is designed to be a resource for teams looking for step-by-step instructional for building
the basic chassis and structure needed in a FIRST Tech Challenge competition. There are multiple versions of
this guide, previously called the “Push Bot Guide”, this version the Basic ‘Bot Guide for REV has been
created to use the new and differing parts in the 2019-2020 season’s REV kit of parts.

Parts
• Rev FTC Competition Set
• Electronics Modules and Sensors Set
• Control & Communication Set 1 or 2
• (Optional) Only the tools included in the FTC Competition Set will be needed to build the chassis. The
screws and nuts are a standard size and having more tools may allow more students to participate at
the same time.
• (Optional) A ruler is not needed to build this robot, but it is necessary to make sure that the robot is
competition ready.

Tips and Tricks

• Secure the screws/nuts just enough, so parts do not slide/move relative to each other. Overtightening
the screws will damage the aluminum extrusions.
• Make sure that set screws are installed in every axle hub, motor hub, and axle collar.
• Refer to the legend provided in the Kit of Parts, if any parts are unfamiliar.
• Make sure that all assemblies are square. It is hard to drive a crooked robot straight!
• The drive wheels are powered by two DC motors, which are relatively heavy. The drive wheels are on
the back of the robot, because that is where the most weight is. This weight is needed to help the
wheels grip the surface better.
• Omni wheels are on the front of the robot, which allows the robot to turn more easily. The omni wheels
can slide sideways with very little friction due to the rollers.

Unless otherwise noted, the top image in each step shows the necessary parts; the lower image shows the
completed assembly.

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Construction
Parts Needed:
Drive Assemblies and Frame REV-41-1303 – Bracket, Motion (4)
REV-41-1361 – Nut, Locking, M3 (8)
Step 1: Build Drive Brackets REV-41-1359 – Screw, Hex Cap, M3, 8mm (8)

Figure 1- Unassembled view

Figure 2- Assembled view

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Parts Needed:
REV-41-1300 – Core Hex Motor w/cables (2)
Step 2: Build Motor Assemblies REV-41-1359 – Screw, Hex Cap, M3, 8mm (3 per motor; 6 in total)
Drive Bracket Assemblies – (1 per motor; 2 in total)

Figure 3- Unassembled view

Figure 4- Assembled view

• Make sure that the brackets are facing the correct direction; the alignment
ribs should be on the side away from the motor.
• Motor directions are reversed – the power plug of the motor pictured on the
left is on the bottom; the plug of the motor on the right is on the top.
• Do not yet plug cables into the motors
• Use only two of the assemblies from step 1.

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Parts Needed:
Step 3: Build the Right and Left Rail REV-41-1432 – Extrusion, 420mm, 90-90 degree (1 per side; 2 in total)
REV-41-1324 – Spacer, 3mm (3 per side; 6 in total)
REV-41-1327 – Shaft Collar (1 per side; 2 in total)
REV-41-1326 – Bearing, Through Bore, Short (1 per side; 2 in total)
REV-41-1347 – Shaft, 5mm Hex, 75mm (1 per side; 2 in total)
Motor Assemblies- (1 per side; 2 in total – from step 2)
Drive Bracket assemblies-(1 per side; 2 in total –the two remaining from step 1)

Figure 5 Unassembled view

(The image above shows only the right rail. Duplicate the number of parts for the left rail.)

Figure 6- Assembled view

• Slide the head of the screws down the center of the extrusions.
The brackets should be flush with the end of the extrusions.
• Order from the outside in: bracket, bearing, spacer, collar, two
spacers, bracket with attached motor

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Parts Needed:
Step 4: Add Drive Wheels REV-41-1354 – Wheel, Traction 90mm (1 per side; 2 in total)
REV-41-1327 – Shaft Collar (1 per side; 2 in total)
REV-41-1324 – Spacer, 3mm (1 per side; 2 in total)
Rail Assemblies (1 per side; 2 in total) *from step 3

Figure 7- Unassembled view

Figure 8- Assembled view

• Order from the outside in: collar, wheel, spacer, rail assembly.
• Make sure that the wheels do not rub the nuts. If they do, then revisit previous steps to make sure
the construction is accurate.
• Adjust axle length, so it is flush with the collar

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Parts Needed:
Back Support Beam REV-41-1320 – Bracket, Inside Corner (2)
REV-41-1359 – Screw, Hex Cap, M3, 8mm (8)
Step 1: Add Screws to Corner Brackets REV-41-1361 – Nut, Locking, M3 (8)

Figure 9- Unassembled View

Figure 10- Assembled view

• Screw the nuts onto the screws just until it’s difficult to turn them; do not overtighten! The
screw heads will need to slide along the center of an extrusion in a later step

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Parts Needed:
Step 2: Add Corner Brackets to Beam REV-41-1431 – Extrusion, 225mm, 90-90
Degree (1)
Corner Bracket Assemblies (2 - from step 1)

Figure 11- Unassembled View

Figure 12- Assembled view

Slide the head of the screws down the center of the extrusion.

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Parts Needed:
Step 3: Add Floating Screws to Beam REV-41-1359 – Screw, Hex Cap, M3, 8mm (2)
Back Support Assembly (1 - from step 2)

Figure 13- Unassembled View

Figure 14- Assembled view

• The two 8mm screws are loaded onto what will become the top face of
the beam.

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Parts Needed:
Step 4: Add Back Support Beam Chassis (from Drive Assemblies and Frame,
step 4)
Back Support Beam Assembly (from the
previous step)

Figure 15- Unassembled view 1 Figure 16- Unassembled view 2

Figure 17- Assembled view

• The beam should touch the drive wheel brackets.

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Front Support Beam Parts Needed:

REV-41-1320 – Bracket, Inside Corner (2)
REV-41-1359 – Screw, Hex Cap, M3, 8mm (8)
Step 1: Add Screws to Corner Brackets REV-41-1361 – Nut, Locking, M3 (8)

Figure 18- Unassembled view

Figure 19- Assembled view

• Screw the nuts onto the screws just until it’s difficult to turn them; just so that the
nuts don’t fall off.
• The screw heads will need to slide along the center of an extrusion in a later step.
•

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Step 2: Add Corner Brackets to Beam Parts Needed:

Front Beam Assembly (1 - from step 2)
REV-41-1431 – Extrusion, 225mm, 90-90 Degree (1)
Corner Bracket Assemblies (2 - from step 1)

Figure 20- Unassembled view

Figure 21- Assembled view

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Parts Needed:
Step 3: Add Floating Screws to Beam REV-41-1359 – Screw, Hex Cap, M3, 8mm (3)
REV-41-1360 – Screw, Hex Cap, M3, 16mm (2)
Front Beam Assembly (1 - from step 2)

Figure 22- Unassembled view

Figure 23- Assembled view

• Two of the 8mm screws are loaded onto what will become the front face of the
beam.
• One of the 8mm and two of the 16mm screws are loaded onto what will become the
top face of the beam.
•

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Parts Needed:
Step 4: Add Front Support Beam
Chassis (from Back Support Beam, step 4)
Front Support beam assembly (1 - from step 3)

Figure 24- Unassembled view 1 Figure 25- Unassembled view 2

Figure 26- Assembled view

• There should be 121mm between the back support beam and the front support
beam (there will be 136mm center to center).
o If a ruler is not available, the position may need to be adjusted in a later
step.

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Parts Needed:
Step 5: Add Switch Bracket REV-41-1361 – Nut, Locking, M3 (2)
Chassis
Switch Plate (part of REV-31-1387)

Figure 27- Unassembled view

Figure 28- Assembled view

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Caster Wheels Parts Needed:

REV-41-1303 – Bracket, Motion (2 per side, 4 total)
Step 1: Build Caster Brackets REV-41-1361 – Nut, Locking, M3 (2 per bracket, 4 per side, 8 total)
REV-41-1359 – Screw, Hex Cap, M3, 8mm (2 per bracket, 4 per
side, 8 total)

Figure 29- Unassembled view

Figure 30- Assembled view

• Screw the nuts onto the screws just until it’s difficult to turn them; do not
overtighten because the screw heads will need to slide along the center of an
extrusion in a later step.

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Parts Needed:
Step 2: Add Caster Brackets to Chassis Caster Bracket Assemblies (4 from the
previous step)

Figure 31- Unassembled view 1 Figure 32- Unassembled view 2

Figure 33- Assembled view

• Brackets must be installed 2 cm from the end of the extrusion, if used for competition,
to fit within the sizing cube.
• Ensure that the pair of brackets on the same extrusion are the same distance from the
end of the extrusion or the wheels will not rotate properly.

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Step 2: Add the Omni Wheels

Parts Needed:
REV-41-1327 – Shaft Collar (2 per side – 4 total)
REV-41-1326 – Bearing, Through Bore, Short (2 per side – 4 total)
REV-41-1323 – Spacer, 15mm (1 per side – 2 total)
REV-41-1324 – Spacer, 3mm (1 per side – 2 total)
REV-41-1347 – Shaft, 5mm Hex, 75mm (1 per side – 2 total)
REV-41-1190 – Wheel, Omni 90mm (1 per side – 2 total)

Figure 34- Unassembled view of left wheel (Make a mirror image for the right side)

[Continued on the next page, so detail can be seen more easily.]

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[Continued from pervious page]

Figure 35 Above shows only the right wheel.

(Make a mirror image for left wheel)

Order from the outside in: collar, omni wheel, 3mm spacer, bearing, bracket,
15mm spacer, bracket, bearing, collar.
Adjust axle length, so it is flush with the collar

[Continued on the next page, so detail can be seen more easily.]

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24 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

[Continued from pervious page]

Figure 36- Assembled view

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Parts Needed:
Motor and Sensor Controller REV-41-1166 – Battery Holder Plate (1)
REV-41-1361 – Nut, Locking, M3 (2)
Step 1: Add the Support Plate

Figure 37- Unassembled view

Figure 38- Assembled view

Center the plate on the extrusion.

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26 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Step 2: Add the Rev Robotics Expansion Hub Parts Needed:

REV-31-1153 – Expansion Hub (1)
REV-41-1360 – Screw, Hex Cap, M3, 16mm (2)
(two other screws are already in the extrusion
from an earlier step)

Figure 39- Unassembled view

Figure 40- Assembled view

• Reposition the front support beam, if necessary, to accomplish the proper spacing – the
two floating screws on the front beam need to be at the corners of the expansion hub

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Parts Needed:
5446 - Monoprice USB Cable (1)
Step 3: Add the Expansion Hub to Phone Cable

Figure 41- Unassembled view

Figure 42- Assembled view

• Plug the Mini USB plug into the Expansion Hub

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Parts Needed:
Motor Power Cable (1 – comes with the core hex
Step 4: Add the Left Drive Motor Power Cable motor – REV-41-1300)

Figure 43- Unassembled view

Figure 44- Assembled view

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Parts Needed:
Step 5: Add the Right Drive Motor Power Cable Motor Power Cable (1 – comes with the core hex
motor – REV-41-1300)

Figure 45- Unassembled view

Figure 46- Assembled view

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30 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Parts Needed:
Robot Controller REV-41-1166 – Battery Holder Plate (1)
REV-41-1359 – Screw, Hex Cap, M3, 8mm (2) (a third
Step 1: Add the Phone Support Plate screw is already in the extrusion from an earlier step)
REV-41-1361 – Nut, Locking, M3 (3)

Figure 47- Unassembled view

Figure 48- Assembled view

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Step 2: Add the Robot Controller Cell Phone to the Holder Parts Needed:
REV-41-1161 - Zip Tie, 160mm (2)
Cell phone configured as the robot controller

Figure 49- Assembled view

Figure 50- Assembled view

It is recommended that an approved material such as non-skid be layered

between the phone and the plate to prevent damage to the phone.
The foam that comes in the phone’s packaging works well for this.

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32 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Step 3: Connect the Robot Controller to the Expansion Hub (Part 1) Parts Needed:
USB On the Go (OTG)
Adapter Cable (1)

Figure 51- Unassembled view

Figure 52- Assembled view

• Plug the Micro USB plug into the bottom of the cell phone.

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Step 4: Connect the Robot Controller to the Expansion Hub (Part 2)

Figure 53- Unassembled view

Figure 54- Assembled view

• Plug the USB-A socket (from the phone) into the USB-A plug (to the Expansion Hub).

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34 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Power Switch
Step 1: Add the Switch Parts Needed:
REV-31-1387 Switch (1)

Figure 55- Unassembled view

Figure 56- Assembled view

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Step 2: Connect the Switch to the Motor and Sensor Controller

Figure 57- Unassembled view

Figure 58- Assembled view

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36 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Battery
Parts Needed:
Step 1: Add the Battery REV-31-1302 – Slim Battery, 3000mAh (1)
REV-41-1161 – Zip Tie, 160mm (2)

Figure 59- Unassembled view

Figure 60- Assembled view

• Care should be taken to make sure the mounting points for the battery DO
NOT puncture or break the insulation of the battery or battery leads!

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Step 2: Connect the Battery to the Switch

Figure 61-Unassembled view

Figure 62- Assembled view

• Connect the two yellow plugs

• Care should be taken to make sure the mounting points for the battery DO NOT puncture or
break the insulation of the battery or battery leads!

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38 | FIRST® Tech Challenge Basic ‘Bot Guide for REV Part 1

Final Steps

The frame has been built, however programming will be needed to make the robot functional. Testing should
be done to determine whether anything needs to be changed or optimized for the season’s game rules. It will
also show whether more cables need to be secured or re-routed. Numbers and other stickers will be needed
to make the robot competition ready.
Check the game rules for all the applicable stickers- The Game Manual Part 1 includes a robot inspection
checklist. FIRST strongly recommends that you go through the robot inspection checklist before a competition
to be sure that you are prepared on the day of competition and don’t have any disallowed parts on the robot.

Visit the FIRST website for programming instructions.

Special Thanks and Best Wishes

FIRST® Tech Challenge would like to sincerely thank the creators of this document Dave and Lydean
Spangler. The Spangler’s have worked tirelessly over many years and seasons to create, update and
improve this document to give teams a “how to” guide for building the robot chassis of the robot to build upon
and improve. We are forever grateful for their help and support in this endeavor.

Please direct any questions or comments about this guide to: firsttechchallenge@firstinspires.org and put
“Questions about the Robot Chassis Build Guide for REV” in the subject line and we will redirect the emails to
the appropriate responders.

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Appendix A – Resources

Game Forum Q&A

http://ftcforum.usfirst.org/forum.php
Anyone may view questions and answers within the FIRST® Tech Challenge Game Q&A forum without a
password. To submit a new question, you must have a unique Q&A System User Name and Password for your
team.

FIRST Tech Challenge Game Manuals

Part 1 and 2 - https://www.firstinspires.org/resource-library/ftc/game-and-season-info

FIRST Headquarters Pre-Event Support

Phone: 603-666-3906
Mon – Fri
8:30am – 5:00pm
Email: Firsttechchallenge@firstinspires.org

FIRST Websites
FIRST homepage – www.firstinspires.org
FIRST Tech Challenge Page – For everything FIRST Tech Challenge.
FIRST Tech Challenge Event Schedule – Find FIRST Tech Challenge events in your area.

FIRST Tech Challenge Social Media

FIRST Tech Challenge Twitter Feed - If you are on Twitter, follow the FIRST Tech Challenge Twitter feed for
news updates.
FIRST Tech Challenge Facebook page - If you are on Facebook, follow the FIRST Tech Challenge page for news
updates.
FIRST Tech Challenge YouTube Channel – Contains training videos, Game animations, news clips, and more.
FIRST Tech Challenge Blog – Weekly articles for the FIRST Tech Challenge community, including Outstanding
Volunteer Recognition!
FIRST Tech Challenge Team Email Blasts – contain the most recent FIRST Tech Challenge news for Teams.

Feedback
We strive to create support materials that are the best they can be. If you have feedback about this manual, please email
firsttechchallenge@firstinspires.org. Thank you!

Gracious Professionalism® - “Doing your best work while treating others with respect and kindness - It’s what makes FIRST, first.”