Step 8: Assemble the Knee Housing

Take the thigh assembly from Step 7 and lay it flat on the surface such that the L-shape part 600_12A is facing upward toward the ceiling.

Take part 600_10C and oriented it such that the knee cap is on top of the L-shape piece of part 600_12A.

Slot the thigh assembly into part 600_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 right so we can see the part of the thigh assembly with the bearing on the actuator facing upward toward the ceiling. Take part 600_08A and fit it on to the groove on part 600_10C, such that the protrusion fits into the bearing and then all the holes on part 600_08A align with the threaded insert on part 600_10C.

Take 9 of M3x10 Flat bolts and lightly tighten into all the holes on part 600_08A to align it with part 600_10C. After the parts are aligned:

• remove 9 of M3x10 Flat bolts one at a time in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 600_08A and part 600_10C.

Flip the current assembly 180 degrees to the other side such that part 600_08A is now facing downward toward the surface. You should be able to see the actuator shaft facing toward the ceiling.

Take 2 of 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 600_10C. This makes it easier to align with part 600_09A later on. Remove 2 of M3x18 Socket bolts after you are done.

Align part 600_09A with the actuator such that the 6 holes nearer to the center of part aligned with the threaded holes on the actuator.

Reuse 2 of M3x18 Socket bolts removed earlier and add 4 more, for 6 total. Lightly tighten them into the 6 holes near the center of part 600_09A to align the part with the actuator and the groove on part 600_10C.

After the parts are aligned:

• remove 6 of M3x18 Socket bolts one at a time in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 600_09A and the actuator together.

Take 9 of M3x10 Flat bolts and lightly tighten into all the holes on part 600_09A to align it with part 600_10C. After the parts are aligned:

• remove 9 of M3x10 Flat bolts one at a time in a star formation,
• apply threadlocker,
• then tighten them back to secure Part 600_09A and part 600_10C.