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Originally Posted by Team3324
Ok so we tried the plastic and it helped slightly but did not completely resolve the problem. We are currently working on a jig to C-clamp the chassis to. We hope that we can then level it by slowly tightening it to a level surface with the C-clamps
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This should work. I am guessing that when you welded the frame together that it expanded and contracted making it not square. So just like they do on automobiles you need to straighten out the frame on a big flat table with a bunch of clamps and straps to yank it back into proper shape. I know our team uses a big welding table that is square and flat and also is topped with a piece of 3/8" steel plate. That way we can weld tabs to clamp on to or other jigs to help facilitate the straightening process.
When flexing it back into shape you will probably need to flex it beyond square because the aluminum will spring back slightly as well.
If you cant bend it back I would suggest cutting some of the welds and then slowly bend it back into square. Then once you have measured your frame to insure squareness, slowly weld each of the cut welds from before.While doing this make sure to equally heat up each area to try and minimize the expansion and contraction caused by welding. I know our welding mentor will go around to each weld on the piece we are fabricating only welding about 1/4 of the area and then moving on to the next one to insure equal heating.
Mostly, however, I find that once the students start building a robotics project, they are too busy learning for me to teach. - dtengineering [more] 
30-01-2014, 23:44
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