Build Plan and BOM

Building a complicated product can be daunting at first, but we created a comprehensive, step-by-step guide to go from the raw materials to a fully functional product. The following document covers the materials used to build our product, machining our parts to specifications, initial set-up, and the regular assembly of the product.

Bill of MAterials

Build Plan

Step 1: Cutting PVC Pipes

Cut 10ft PVC Pipes into proper lengths for the frame:

1. Use a measuring tape and marker to mark lines and cut for each piece
2. Cut 72in pipes off of the 10ft PVC Pipes

NOTE: There should be three 48in PVC pieces and one 49.125in piece left

1. Cut two of the 48in PVC Pipes into 12in and 36in lengths
2. Cut the remaining two long PVC pipes into lengths of 30in, 15in, and 2.625in

NOTE: There should be 0.375in and 1.5in scrap PVC pieces that can be discarded

Step 2: Drill Main Pipes

Net Screws
- Mark 15 dots for the screw holes, referencing the Inventor drawings for exact measurements, repeat this for each of the 4 pipes
- Using a 5/32 drill bit, drill through the PVC at every marked dot.

Pin Screws
- Mark 2 dots for the screw holes, referencing the Inventor drawings for exact measurements, repeat this for each of the 2 pipes.
- Using a 3/8 drill bit, drill through the PVC at the marked dot.
Feed a 2in screw through each 5/32 hole drilled. There should be a total of 60.
Fasten each screw by adding nuts on both sides of the screw, tightening it to the PVC pipe. Leave at least 1/2in of the screw exposed, allowing ample space to hook a net around it.
Make sure the metal pins friction-fit into the two ⅜ drilled holes.

Step 3: Drill Leg Pipes

Mark 5 points on the 3ft leg pipes, referencing the Inventor drawings
Use a 3/8 inch drill bit to drill in the holes.

Step 4: Drill Brace Pipes

Mark a dot 0.35 inches on each end and side of the pipe two 30 inch brace pipes.
Use the 3/8 inch drill bit to drill holes in those 4 spots. Test the fit with the 4 pins through each hole.
File or sand holes so pins slide in with slight friction

Spacers:

Use PVC cutter to cut spacer CPVC into correct lengths
Cut four pieces at 1.185in lengths, use a caliper to get a precise measurement
Cut four pieces at 1.25in lengths, use a rule for measurement

Step 5: Connect Technology

Drill holes for LED in each quadrant referencing the Inventor drawings for exact measurements.
Cut wires for each quadrant.
- Two 72 in lengths for each top LED
- Two 4 in lengths for each bottom LED
- 4 36 in lengths for the extension wires in the bottom pipe
Feed 72 in lengths of wire through the side pipe and through the LED holes
Feed 4 in lengths through the bottom of the side pipe into the LED hole
Insert heatshrink and and solder wires to LED leads
Glue LEDs to the pipe
Glue LED Case on top of the LED with curved edge matching the pipe
Drill two extension wire holes in the middle of the bottom pipe with Inventor drawings
Feed 36 in lengths through the bottom pipe through the holes in the middle and the T-connector on the other side
Crimp DuPont connectors on each end of the wires
- Two 4 by 1 connectors at the bottom of the side pipes for each two LEDS
- Two 4 by 1 connectors on the extension wires at the T-connector
- One 8 by 1 connector at the middle of the bottom pipe connecting all 4 LEDs to the Arduino breadboard
Hot glue wires in place on the inside of the pipes

Step 6: Assembly

Unpack pre-assembled parts:
- Bottom pipe with T-connectors on both ends
- 2 Leg pipe assemblies with End caps, T-connectors, and 2.625in connector
- Side Pipes with screws and LEDs
- Top pipe with elbow connectors
Connector bottom pipe to the T-connectors on the leg pipe assemblies on both ends
Attach DuPont connectors on the bottom of the side pipes to the T-connectors on the bottom pipe
Insert side pipes into T-connector on the bottom pipe
Insert elbow connectors on both ends of the top pipe into the top ends of the side pipe
Attach brace pipes to leg pipe holes with the metal pins
- Insert Pin on the outside of the leg pipe
- Insert the red spacer (1.185 in) on the pin in between the brace pipe and the leg pipe
- Insert the brace pipe through the pin
- Insert the green space (1.25in) onto the pin after the brace pipe
- Screw hex bolt nut
Attach brace pipe to hole on the side pipe using same process above
Stretch net over the frame with the screw pegs, and clip carabiner hooks at the corners
Optional: Hook tension rope onto the hooks at the end of the base legs
Plug 8 by 1 DuPont connector into breadboard and flip power switch.

Original Build Plan: Link

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