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How to build a Heavy Duty 4WD ATR
How To Build A Robot

How To Build a Heavy Duty 4WD Robot

These videos will walk you through building our Heavy Duty 4WD All Terrain Mobile Robot Platform with 52mm Motors but these can also be used to build the following robots as well:

Please note that this platform is for ages 16 and and requires some mechanical and electrical skills as well as some basic hand tools. This is a professional development robot platform with a robust welded chassis and quality components. Each wheel is supported by two durable double sealed bearings which allows the robot to hold a lot of weight. The chassis is made of 1/8 thick aluminum, which is easy to drill into, allowing this platform to be customized to fill your requirements. It is not a cheap, limited, snap-together kit. If you do not feel comfortable assembling this platform, we can assemble it for you for an extra charge. If you have questions feel free to Contact Us.

Parts List (Mechanical Assembly Only):


Part 1: Steps 1, 2 and 3

This video shows how to mount the motors, bearings, and motor sprockets.

Step 1: Mount motors to chassis

The chassis has a pattern of slots where each motor will mount. Place a motor plate between motor and chassis and insert screws. Use thread lock on each screw to prevent them from loosening. Use washers between chassis and screw head.

Step 2: Step 2: Insert bearings

The chassis has 12 bearing holes. We will be using the outer eight. The bearings will press in by hand.

Step 3: Mount Sprockets to Motors

The wheels in this robot are chain driven so we will need to mount sprockets to the motor shafts and later to the axles. These are the 14 tooth sprockets with the 12mm bore. Before mounting sprockets, approximate how far out on the shaft the teeth need to be to line up with mating sprocket on the axle. Unscrew set screws and place sprockets on motor shaft. Tighten set screws making sure to tighten the first one to the flat spot on the motor shaft. Use thread lock and make sure set screws are very tight to prevent any backlash.

Tools used in this video:

  • Phillips Screwdriver
  • Thread-locking fluid
  • 1/8 Allen wrench
  • Pliers
  • Rag

How to Size and Cut Roller Chain

Learn how to cut roller chain from the experts.

Measuring the chain

To measure the chain simply place the chain in the sprockets and mark where you would make the connection. Note that to connect the chain a connecting link will need to be put in that will take the place of another link. So you would need to remove the link that you marked and replace it with the connecting link.

Cutting the chain

There are many different tools you can use to cut the chain. In the video we use an angle grinder but other tools like a Dremel or a hand file will also work. To cut the chain you want to file down the rivets that fasten the links. Once the rivets are filed down enough, you can remove the link you marked and replace it with the connecting link.

Installing the chain

Now you have your chain cut to size you can connect the two ends with the connecting link and install it. Note that one side of the connecting link will protrude from the chain farther than the other side. You will want to orient the chain so that this protrusion on whichever side has more clearance.

Tools used in this video:

  • Sharpie marker
  • Angle grinder
  • Screwdriver
  • 1/8 Allen Wrench

Part 2: Steps 4 and 5

In this video we will be installing the chains.

Step 4: Couple axles to motors

Loosen motors and slide them in the slots closer to the axles. Slide a lock collar onto axle and slide axle through first bearing. Slide a 14 tooth sprocket (1/2 bore) onto the axle first and then slide the 21 tooth sprocket on so it aligns with the motor sprocket. Orient both hubs toward the center of the chassis to allow room for the chain. Insert chain around the 21 tooth sprocket and the motor sprocket. Finally, slide the axle through the second bearing and place a lock collar so that it is flush with the end of the shaft. Tighten the set screws on the lock collars and tension chain by moving motor away from the axle in slots and tightening screws. Note that if you are not opting to couple front and rear axles you will leave the 14 tooth sprocket out of the axle assembly.

Step 5: Couple front and rear axles (optional)

Fish chain through the chassis and around both 14 tooth sprockets on the front and rear axles. Insert splice between two chain ends.

Tools used in this video:

  • Screwdriver
  • 1/8" Allen Wrench
  • Thread-locking fluid

Part 3: Steps 6 and 7

In this video we will be fixing the set screws in the sprockets to the axles and mounting the wheels.

Step 6: Fix sprockets to axles

In this step we will be drilling a dent in the axle to make a secure connection between the sprocket and the axle. The dent should be just deep enough to fit the bottom of the set screw (the chamfered edge underneath the threads). Make sure the set screws in lock collars are secure so that the axle cannot slide back and forth in the bearings. Also make sure the teeth on all mating sprockets are lined up. Start by tightening one of the set screws on a sprocket and then remove the other. Use a 15/64 drill bit to center dent in set screw hole but be careful not to damage the threads. Change to the 13/64 drill bit to finish dent. Insert set screw with thread lock and tighten it into the dent. Remove the other set screw to place thread lock and secure it again. Repeat process for all sprockets on the axles.

Step 7: Mount wheels to axles

Remove all hardware from the wheel plates. Mount wheel to axle using provided hardware. Make sure all screws are in place before tightening nuts all the way. Also make sure that the air valves are on the outside of the robot. Before driving the robot, make sure you inflate the tires. Failure to do so will result in shearing of air valves.

Tools used in this video:

  • Socket Wrench
  • 12mm Socket
  • 14mm Socket
  • Screwdriver

Wiring and Final Assembly

For help wiring and completing assembly please see our IG32 Assembly Videos. For more help and general information, visit our Support Page.



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A practical guide to building a robot from the ground up. We build one of our robot kits in front of a camera so you can see first hand what is required when building a SuperDroid.
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