1. Plywood cutlist BP - Base Plate (Dock item#1) BR - Base Rack
4ea 23-7/8” square
BR - Base Rack
4 ea 7-7/8 x 15-7/8”
SR - Spotter Rack
4 ea 7-7/8 x 11-7/8”
HR2 –Hinge Reinforcement
Under Scoring bin : 4 ea 9 x 11-7/8”
HR3 –Midway Beam Hinge Mount : 4ea 7-7/8 x 7-7/8”
LS - Lazy Susan Cargo Turntable : 4 ea 9”x9” BP BP 24 9 8 BP BP LS LS LS LS
HR2
HR2
HR2
HR2 BR BR
HR3
HR3 BR BR
HR3
HR3 SR SR SR SR

2. Plywood cutlist instructions:
Starting square is (BP) 24”less kerf: about 23-7/8” After cutting the 24” squares, take care to follow the cut list and cutting instructions or everything wont fit in one sheet of plywood!

3. 2x4 cutlist
item item item 5
36” boat turntable arm /8” platform reinforcement (2) ~6” Tower crossmember feet (2) A
item ” tiebreaker switch
6” solar panel holders (7) standoff (1)
item 3
6” platform feet (8) B
item ” tiebreaker switch
6” solar panel holders (5) ” cargo bin counterweights (4) standoff (3) scrap C
3” bucket bottom
backing blocks (2)
item 3
11” stool supports (4) scrap D
Note: Illustrations not to any (consistent) scale
Cut 4 2x4s as shown in “A.” Cut 1 2x4 as shown in “B” and one
as shown in “C” and “D.” Four remaining 2x4s are used full
length for crossmember supports.

4. Foam Sheet Cutlist 12” 6” 6” 6” 6” 6” Slice into 7-7/8” strips
Use 4 strips this way:
1 T blank 11-7/8”
1 T base 5-7/8”
5 Solar panels 5-7/8”
Remaining strips can be used for spares
Or provide teams with solar panels or T’s a a a a a a a a a
T blank a
T base
Solar panel
Solar panel
Solar panel
Solar panel
Solar panel
7-7/8”
4 ea
12” 6” 6” 6” 6” 6” a
Solar panel
Solar panel
Solar panel
Solar panel
Solar panel
Solar panel
Solar panel
Solar panel
7-7/8”
Spares or team parts

5. Foam Sheet Cutlist 2
For bottle soft caps, cut 8 sets of pieces as follows:
1. cut a 2-3/4" diameter circle from the foamboard.
Cut a 1-1/4" diameter hole in the center of this circle,
making a doughnut.
3. Cut a second circle 2" in diameter from the foamboard.
Apply contact cement to the inside of the hole in the
doughnut and push onto the pressurized bottle neck until it is
flush with the top of the bottle cap.
When this is dry, use contact cement to attach the second
circle to the center of the bottle/doughnut assembly, covering
the bottle cap.

6. Instructions
A table saw cuts foam quickly/neatly/easily
But it’s a little messy, be prepared for electrostatic dust
A jigsaw with a fine tooth metal blade also works well (especially for circles)
To avoid foam surface tear-out:
Use a zero-clearance table saw insert
Or set saw to ½” depth of cut and make one pass from each side, feeding from back of the table so that saw teeth are cutting on the upswing into foam. (not yet tried)
Measure and cut one solar panel hole, then use it as a template for the remaining panels
Hole-saw cuts foam more cleanly when set to reverse direction
To avoid back surface tear-out with hole-saw on plywood &foam:
Cut only half way through from first side, then flip sides to finish hole.
This also makes it much easier to remove plug of material from saw!

7. Notes on plywood cutsheet drawing updates
Lazy susan square needs to be > 6*sqrt2=8.5, so 9 inches will work
Spotters rack and HR2 are same size 8x12 (less 1/8” kerf)