Locate the base plate (servo mount).

Mount the servos, using 3/8" Philips 4-40 screws, and using the include #1 Philips screwdriver. Tighten well. NOTE: Do not force the threads, as you may strip them. They should not be difficult to install. If you do, by mistake strip a hole, then use the included nuts in the spare hardware kit. When placing the servo in the hole, the drive axle should be centered on the unit.

Next, locate the wheels.

Place the wheel on the axle, and insert the #4 - 1" long self-tapping philips screw into the hole in the wheel. Tighten, all the while watching to keep it centered in the whole. This will minimize wobble. Do not over tighten, as the axle is only plastic and you don't want to strip it out.

Locate the battery mounting holes on the base plate. Affix the Velcro strip for the battery pack and mount it so it is align with, and centered on the two holes closest to the servos.

Then, take the two small Velcro dots and affix them to the bottom of your NiCad battery pack so that they will stick to the the base strip when placed in position.

The battery cable should be facing the center of the base and the servo cables should be fed toward the battery before the next step so they can be fed through the back grommetted pass through hole for connection.

Locate the 2nd Level kit, and the robot brain mounting kit. Mount 4 hex threaded standoffs in each of the 4 corners indicated in the picture (You can also use the OOBoard to align the holes on the level 2 plate. They should align with the four mounting holes on the corners of the OOBoard). You should have 4 - 4-40 1/4" pan head Philips screws remaining for mounting the OOBoard later. You should not tighten up these standoff just yet, tighten them up after you mount the OOBoard so it aligns easier.

You can also mount the sensor mount and IR ranger sensor now if you like, it can be a bit easier but not necessary to do it now.

Now you can mount the level with its 6 screws remaining in the base/servo/battery mounting kit. You might need to squeeze the base risers together a tad to get the holes on the second side to line up depending on the metal flare.

At this time you should feed the battery extension cable through the center pass through hole.   BUT DO NOT CONNECT THE BATTERY to this cable at this time.  (not until the OOBoard is connected to the bare wires on the end.

Finally, mount the OOBoard to the 4 standoffs using the 4 screws remaining in the robot brain mounting kit. If the holes don't line up perfectly loosen up the standoffs and don't tighten up the screws through the OOBoard until all 4 are in place. Then you can tighten all the screws up nice and tight. The OOboard should have the battery extension cable underneath it. (You can place you breadboard on the 4 Velcro dots anytime in this phase)

Route the servo cables through the back grommetted pass through hole. Attache them to the servo connectors on IOLine 29 and 30. You might want to mark them now so you can connect them the same way if you should take it apart. The brown wire should be closest to the back edge of the board.

NOTE: The colors correspond as: Brown = Black (GND), Red = Red (Pwr- Max 6V), Orange = white (signal-PWM)

Finally, you can screw the battery extension cable bare ends into the green power connectors. The black lead should connect to the end with the BATT label beside it or closest to the DB9 serial connector. Tighten them down well. When you have connected the battery extension cable, you can connect the battery up from underneath between the servos.