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Assembly Instructions

A parallel assembly video is also available.

Step 1: Heat-Set Inserts

CARVE Core chassis parts, PCB, and motors before assembly

First, add heat-set inserts to the parts shown below.

Printed parts that require heat-set inserts

Most heat-set insert placement is straightforward. Every hole measuring 4.2–4.3 mm is intended to receive an insert. The pictured parts do not show them, but newer CARVE Core revisions should have indicator rings around the insert locations. A ring identifies both the location and the insertion side. This distinction is important on the bottom base plate.

Soldering iron positioned above a heat-set insert Installing a heat-set insert into a printed part

The center chassis requires inserts on the top, bottom, and sides. Each motor-mounting position needs only the four outer inserts rather than all six available locations.

Top and bottom chassis faces with heat-set inserts installed Installing heat-set inserts in the side of the center chassis Center chassis with side heat-set inserts installed

Next, add the heat-set inserts to the top plate.

Heat-set insert locations on the top plate Top plate with heat-set inserts installed

The bottom plate is slightly more involved. The module inserts belong on one side and the remaining inserts on the other. Their orientation matters because the PCB mount is asymmetrical. If the model has indicator rings, follow them. Otherwise, align the PCB-mounting holes to identify the correct side.

Bottom plate aligned with the center chassis

Once the PCB-mounting holes are aligned, install their inserts and the battery-mount inserts from that side. Install the module inserts from the opposite side.

Bottom plate with heat-set inserts installed

The PCB mount also requires heat-set inserts in its outermost corners.

Step 2: Motors

Install the motors in their mounts. Each motor requires six small M3 screws.

Motors, mounts, and screws before assembly Motors installed in their printed mounts

Attach the assembled motor mounts to the chassis.

Motor assemblies positioned around the center chassis Motor assemblies attached to the center chassis

Step 3: PCB

The PCB acts as a breakout board for the rover components. Install the required female headers, JST XH connectors, and XT60 connector, then solder them to the board.

PCB and connectors before soldering PCB with headers and connectors installed

Step 4: Final Assembly

Install the battery clips, chassis plates, and remaining components as shown below.

Printed battery-mount component Battery clips installed on the battery Battery-mount clips installed in the chassis Internal chassis components assembled Completed CARVE Core chassis