Materials and Tools

File:Athena pilot hole materials.JPG Materials Description Count 240mm x 42mm motor end plywood linking board 3 210mm x 42mm idler end plywood linking board 3 605mm x 50mm vertical boards 3

File:Athena pilot hole tools.JPG Tools 2mm (1/16") drill bit 3mm (1/8") drill bit Drill motor Sharp pencil Right side pilot hole template Left side pilot hole template Vertical board hole template

Note

• Pilot holes facilitate assembly but are not necessary, especially if Baltic Birch plywood is used.
• Try not to drill pilot holes all the way through the linking boards.
• Linking board mounting screws are located in difficult-to-reach locations and pilot holes can simplify assembly of the motor and idler ends.
• The holes in the vertical boards are through-holes, passing through the entire length of the board.
• To minimize swelling and shrinking due to changes in humidity, sealing the plywood is recommended.

Procedure

See video instructions on Motor End Assembly for similar instruction.

Linking Board Pilot Holes

1. File:Athena linking board templates.JPG

   There are two linking board pilot hole jigs for accurately locating the positions of pilot holes. One each for the left and right sides of the boards. Ream the holes in the triangular pattern with a 3mm (1/8") drill bit.

2. File:Athena mark linking board.JPG

   Stack the linking boards so that their edges are up and mark that edge with a pencil.

3. File:Athena linking jig.JPG

   Place one of the pilot hole jigs on the end of a board with the marked edge of the board on the same side as the narrow stop at the bottom of the jig. Push the board firmly into the jig and with a sharp pencil, mark the location of the pilot holes. Repeat with the other jig on the opposite end of the board ensuring that the marked edge is towards the bottom of the jig.
4. Repeat with the remaining linking boards.

5. File:Athena Delta drilling pilot linking.JPG

   Drill 2mm (1/16") pilot holes at the marked positions on each board being careful to not drill all the way through the board.

File:Athena drilled linking.JPG

Vertical Board Through Holes

1. File:Athena vertical board template.JPG

   Locate the vertical board through hole template and ream the holes with a 3mm drill bit.

2. File:Athena mark vertical board.JPG

   Butt the template against one corner of a board as shown in the picture and mark the locations with a sharp pencil. Repeat on the opposite end of the board. Mark all three vertical boards.

3. File:Athena drill vertical board.JPG

   Drill through the board with a 3mm drill bit.

File:Athena drilled vertical.JPG

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