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Module 4 — Assembly & QA

Objective: assemble reliably and catch issues early.

Prereqs: Fabrication packet and parts on hand.

Steps

  • Follow torque and threadlocker checklist; align shafts/gears and verify free spin.
  • Check clearances and interference at full travel; verify chain/belt tension.
  • Record any rework items and owners.
  • Confirm fastener redundancy on critical joints (nylocks + threadlocker where needed).
  • Spin-test mechanisms manually before powered tests; listen for rubbing or binding.

Deliverables

  • Assembled subsystem with QA checklist and rework list (if needed).
  • Sign-off sheet with torque checks and tension checks completed.

Instructions (numbered)

  1. Assemble per order of operations; apply torque/threadlocker where specified.
  2. Align shafts/gears; verify free spin and no rubbing; adjust as needed.
  3. Check clearances through full travel; set belt/chain tension properly.
  4. Confirm fastener redundancy on critical joints; mark torqued fasteners if desired.
  5. Spin-test manually, then low-power test; log issues and owners.

Example

  • Shooter: torque 1/4-20 to spec with blue Loctite; chain tension set to 0.25" slack; spin by hand, then at 20% power to check vibration.

Best practices

  • Use a printed checklist; mark completed items.
  • Re-check tension after first run-in.
  • Keep threadlocker away from plastic where it can cause damage.

Common mistakes

  • Skipping torque checks; overtightening and crushing bearings.
  • Running at full power before manual/low-power tests.
  • Leaving debris/shavings in assemblies.

Checklist

  • Torque/threadlocker applied per notes
  • Free spin verified
  • Tension set and rechecked
  • Full travel clearance checked
  • Issues logged with owners

Recommended tools

  • Torque wrench/driver, threadlocker, feeler/tension gauge (or measured slack), checklist printout.

Sample log (template)

  • Date:
  • Subsystem:
  • Checks done:
  • Issues found:
  • Rework owner/date:

Photos/diagrams

  • [Placeholder: photo of assembled subsystem with callouts for torque/tension points]

Resources

  • Use BOM notes for torque specs and threadlocker locations.