Step 8: Assemble the Knee Housing

Take Sub Assembly A and lay it flat on the surface such that the L-shape part 500_12A is facing upward toward the ceiling.

Take part 500_10C and oriented it such that the knee cap is on top of the L-shape piece of part 500_12A.

Slot Sub Assembly A into part 500_10C such that the two actuator holes are aligned with the knee portion first to help us estimate how the part will fit together.

Turn the leg toward the left so we can see the part of Sub Assembly A with the bearing on the actuator facing upward toward the ceiling. Take part 500_08A and fit it on to the groove on part 500_10C, such that the protrusion fits into the bearing and then all the holes on part 500_08A align with the threaded insert on part 500_10C.

Take 9 – M3x10 flat bolts and lightly tighten into all the holes on part 500_08A to align it with part 500_10C. After the parts are aligned:

• remove each of the 9 – M3x10 flat bolts in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 500_08A and part 500_10C.

Flip the Sub Assembly A 180 degree on the other side such that part 500_08A is now facing downward toward the surface. You should be able to see the actuator shaft facing toward the ceiling.

Take 2 – M3x18 socket bolts and lightly tighten into the threaded holes on the actuator shaft. Make sure that the bolts are on the opposite side of each other, use those bolts as the leverage to turn the actuator shaft so that the bolts is on a straight line with the rest of part 500_10C. This makes it easier to align with part 500_09A later on. Remove the 2 – M3x18 socket bolts after you are done.

Align part 500_09A with the actuator such that the 6 holes nearer to the center of part aligned with the threaded holes on the actuator.

Reuse the 2 removed M3x18 socket bolts and add 4 more, for 6 total. Lightly tighten them into the 6 holes near the center of part 500_09A to align the part with the actuator and the groove on part 500_10C.

After the parts are aligned:

• remove each of the 6 – M3x18 Socket bolts in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 500_09A and the actuator together.

Take 9 – M3x10 flat bolts and lightly tighten into all the holes on part 500_09A to align it with part 500_10C. After the parts are aligned:

• remove each of the 9 – M3x10 flat bolts in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 500_09A and part 500_10C.