Step 17 says “Attach one crossed servo horn to each triangular (6 in all) on the bottom body plate.” indicating the smallest screw in the image be used. As it turns our, none of the provided screws are large enough to engage the body plate, the holes in the body plate being too large. I plan to check with local hardware store to see if I can find either a appropriately sized screw that does not destroy the servo horn or possibly a nut and bolt and then drill out a larger hole in the servo horn. Anyone have an alternative solution? Maybe superglue?
Cecil
Ah, yes. I just had the same problem with mounting the servo horn on hexy’s head. I cut a strip of the u-grooved seal from one of the zip-lock bags with a utility knife, and inserted one end into the oversized hole, inserted the screw, then trimmed the remaining plastic away on the other side of the hole. Worked fine.
The servo horn screws work in shear, so they just have to be snugly in place and not fall out. They don’t have to resist a lot of tension to pull them out of their holes.
You can also try flipping the body plate over. The acrylic is laser cut which means the holes are not the same diameter top and bottom, they are more of a V shape.
I suppose everyone with a 1st generation Hexy must have this problem. My solution was to screw the screws all the way on the servo horn, put the horn in place with the screws having a clearance fit in the body plate, then squirt hot-melt glue into the holes from the other side, and trimming excess glue away with a craft knife
I used the two long screws from the servo horn bag, and screwed them from the bottom of the Hexy up into the horn. (You’ll have more screws showing on the bottom of the hexy, but I actually like the way it looks.)