improve body build documentation & images - increase nut count (#527)

* improved body and hinge pictures and text

* improved body description and assembly images.  Increased nut count.

* add todo, change color on image (box to hide nuts)

* update body panel image

* Update mechanical/body/README.md

typo

Co-authored-by: Achille Verheye <achille.verheye@gmail.com>

* remove source files for annotations

---------

Co-authored-by: Achille Verheye <achille.verheye@gmail.com>

Author: knickels

mechanical/body/README.md

@@ -1,45 +1,101 @@
 # Main Body Assembly
-
 The body is the housing of all the electronics for the rover and acts as the attachment point for the differential pivot and the body axis that the rocker-bogies on either side connect to.
 
 ![finished body](images/body.png)
 View of the body without PCB and with some of the body plates made transparent.
 
 ## Assemble the body frame
-
 Gather the pieces from the [parts list for the body](../../parts_list/README.md/#parts-for-body-assembly).
+* 4x 41 hole, 328mm square beams
+* 5x 29 hole, 232mm square beams
+* 8x 12 hole, 96mm square beams
+* 26x M4x16 socket screws
 
-Use socket M4 screws of 16mm length and pay close attention to the placement of the beams using the image below and the online OnShape model.
+### Bottom Frame
+Connect 2x 29 hole and 2x 41 hole beams with M4x16 screws as shown.  Be sure to attach the cross beams 1 hole in on the long beams.
+Insert 1 29 hole beam into hole #16, counting from the front of the rover. (TODO: Update image to move crossbar.)
 
-![body frame](images/body_frame.png)
+![body base](images/body_base.jpg)
 
-## Assemble the bearing support structrues that connect to the rocker-bogie
+### Top Frame
+Connect 2x 29 hole and 2x 41 hole beams with M4x16 screws as shown.  
 
+![body base](images/body_top.jpg)
 
-Make two of these and connect them to the sides of the body. They should be installed exactly in the middle, which means that you're going to connect each side to the 17th hole on the long 41-hole beams on the top and bottom of the body frame. Use the M4 16mm socket screws.
+### Verticals
+Connect 8x 12 hole beams along the long edges in holes #1, 17, 25, and 41 on both sides. (TODO: Update image to move crossbar.)
 
-The bearings have a flat side and a 'hollow' side. The hollow sides should both be pointing to the same side, as shown in the image.
+![body verticals](images/body_vertical.jpg)
 
-![bearing support structures](images/rocker-bogie-sleeves.jpeg)
+## Assemble the bearing support structures that connect to the rocker-bogie
 
-## Install the hinges for the top body plates
+Make two of these and connect them to the sides of the body. They should be installed exactly in the middle, which means that you're going to connect each side to the 17th hole on the long 41-hole beams on the top and bottom of the body frame. Use the M4 16mm socket screws.  Use M4x12 screws on the end toward the outside of the rover and M4x8 screws on the end toward the center of the rover end.
+
+The bearings have a flat side and a 'hollow' side. The hollow sides should both be pointing to the center of the rover side, as shown in the image.
+
+![Body Bearing Supports](images/body_bearing_supports.jpg)
+
+Now, install the supports on the 6th hole from the top of the 12 hole beam, and the 5th hole from the bottom.  If it's a bit tight, loosen up the verticals until all the screws are started, then tighten all of them after.
+
+![bearing support structures installed](images/rocker-bogie-sleeves.jpeg)
 
+## Install the hinges for the top body plates
 You will need the 20 or 22mm M4 standoffs, the 3x5 hole plate, the hinge assembly (assemble following the [instructions on GoBilda](https://www.gobilda.com/plastic-hinge-2-pack/), orientation matters).
 
-| ![](images/hinge_assy.jpg) | ![](images/hinges.jpg) |
-| -------------------------- | ---------------------- |
-| ![](images/hinges.png)     | ![](images/hinges2.png) |
+![](images/hinge_parts.jpg) 
+
+First, attach the standoffs to the 3x5 plate with M4x8mm socket head screws
+
+![](images/hinge_step1.jpg) 
+
+Then, attach the plate to the top front and top rear beam, leaving 4 holes to the outside of the plate.
+
+![](images/hinge_step3.jpg)
+
+Finally, attach the hinges to the standoffs, facing the flat part of the plastic to the outside and top as shown, with M4x8 screws
+
+![](images/hinge_installed.jpg)
+
+You will attach the body plate to the top part of the hinge in a later step.
+
+![](images/hinges.jpg) 
 
 ## Make the differential pivot
 
 The Differential Pivot helps to offload forces from one side of the rover to the other while climbing. The differential pivot is crucial in the rocker-bogie suspension system and is designed to help keep all 6 wheels on the ground at all times. It also allows a second attachment point for the body so that it does not freely rotate about the center axes that run through it and connects the two rocker-bogies.
 
-Construct the parts as in the image below, using the appropriate M4 screws where necessary. Use locking M4 hex nuts to fasten the screw passing through the turnbuckles (in blue).
+### Gather the parts
+You'll need the parts shown below.
+
+![parts](images/diff_parts.jpg)
+
+TODO: update image to show M4x6mm button screws instead of the M4x6mm socket head screws show here (and in the CAD)
+
+Assemble the idler bearing hub following the [instructions on GoBilda](https://www.gobilda.com/idler-bearing-hub-32mm-od-16mm-height/).
+
+Connect the block mount to the 7-hole linkage using M4x10mm button-head screws.  Connect the 20mm threaded rod to a steel ball linkage on each end to create two turnbuckles.
+
+![step 1](images/diff_step1.jpg)
 
-![Differential Pivot](images/diff_pivot.png)
+Connect the turnbuckle to the 7-hole bar linkages with an M4x20 socket head screw and lock nut, and to the second hole from the end of the U channel with an M4x16 button head screw and lock nut.  Repeat for other side.
 
-Finally attach the differential pivot to the top of the body using 4 socketed M4 screws. The differential pivot should be able to freely rotate around the body. We'll attach the side of the differential pivot to the rocker-bogies later.
+![step 2](images/diff_step2.jpg)
+
+Connect the differential pivot (the whole assembly) to the idler bearing hub with two M4x6 button-head screws 
+
+![step 3](images/diff_mount_top.jpg)
+
+Add 2x 29 hole, 232mm square beams in holes #28 and 30 from the front, on the longer 41 hole, 328mm beams, using M4x16mm socket head screws.  Mount the idler bearing hub to the crossbars with M4x12mm socket head screws as shown.
+
+![step 4](images/diff_mount_bot.jpg)
+
+The differential pivot should be able to freely rotate around the body. We'll attach the side of the differential pivot to the rocker-bogies later.
 
 ## Install the laser cut body plates
+Use M8x16 button head screws because of their lower profile along with nuts on the inside so the screws don't fall out while driving. 
+If you've completed the PCB assemblies yet, you can attach them to the bottom body plate already, but you can also do this later.
+
+![body with top panels closed](images/body_closed.jpg)
+
+![body with top panels open](images/body_open.jpg)
 
-Use button screws because of their lower profile along with nuts on the inside so the screws don't fall out while driving. If you've completed the PCB assemblies yet, you can attach them to the bottom body plate already, but you can also do this later.