THE UNOFFICIAL LEGO TECHNIC BUILDER’S GUIDE

WHAT WILL YOU BUILD? THE UNOFFICIAL

™

The LEGO® Technic system opens a new realm of building  Build custom differentials, suspensions, transmissions,

LEGO TECHNIC
possibilities. Using motors, gears, pneumatics, pulleys, and steering systems ®
linkages, and more, you can design LEGO models that  Pick the right motor for the job—and transform its proper-
really move. ties to suit your needs
The Unofficial LEGO Technic Builder’s Guide is filled with  Combine studfull and studless building styles for a stun-

BUILDER’S GUIDE
building tips for creating strong yet elegant machines and ning look
mechanisms with the Technic system. Author Paweł “Sariel”  Create remote-controlled vehicles, lighting systems,
Kmiec will teach you the foundations of LEGO Technic build- motorized compressors, and pneumatic engines
ing, from simple machines to advanced mechanics, even
This beautifully illustrated, full-color book will inspire
explaining how to create realistic to-scale models. Sariel, a
you with ideas for building amazing machines like tanks with
world-renowned LEGO Technic expert, offers unique insight
suspended treads, supercars, cranes, bulldozers, and much
into mechanical principles like torque, power translation, and
gear ratios, all using Technic bricks. You’ll learn how to:
more. Your Technic adventure starts now! Paweł “Sariel” Kmiec

®
about the author
 Create sturdy connections that can withstand serious
stress Paweł “Sariel” Kmiec (http://sariel.pl/ ) is a prolific blogger
 Re-create specialized LEGO pieces like casings and and Technic model builder. He is YouTube’s most popular
u-joints, and build solutions like Schmidt and Oldham LEGO Technic builder, a guest blogger for the official LEGO
couplings, when no standard piece will do Technic blog, and a 2012 LEGO Ambassador.

INSPIRATIONAL MODELS, COMPREHENSIVE BUILDING ADVICE, AND

BUILDING INSTRUCTIONS FOR OVER 40 MECHANISMS

T H E F I N E ST I N G E E K E N T E RTA I N M E N T ™ THIS BOOK IS NOT AUTHORIZED OR ENDORSED BY THE LEGO GROUP.

w w w.nostarch.com

PRICE: $29.95 ($30.95 CDN) SHELVE IN: HOBBIES/LEGO

Kmiec
 contents in detail
foreword by Fernando Correia.................................................................................xv

preface...................................................................................................................xvii

acknowledgments..................................................................................................xviii

part I basics

1
basic concepts........................................................................................................... 3
speed...................................................................................................................................................................................... 3
torque..................................................................................................................................................................................... 3
power...................................................................................................................................................................................... 3
friction.................................................................................................................................................................................... 4
traction................................................................................................................................................................................... 4
rolling resistance................................................................................................................................................................. 4
backlash................................................................................................................................................................................. 5
efficiency................................................................................................................................................................................ 5
vehicular concepts............................................................................................................................................................... 5
driveshaft...................................................................................................................................................................... 6
drivetrain...................................................................................................................................................................... 6
driveline......................................................................................................................................................................... 6
steering lock................................................................................................................................................................. 6
turning radius.............................................................................................................................................................. 6
FWD, RWD, 4×4, 4WD, and AWD........................................................................................................................... 7
weight distribution..................................................................................................................................................... 7
center of gravity.......................................................................................................................................................... 7
ground clearance........................................................................................................................................................ 8

2
basic units and pieces............................................................................................... 9
the Technic brick.................................................................................................................................................................. 9
pins, for joining and rotating.......................................................................................................................................... 10
beams, the studless alternative.....................................................................................................................................12
the half stud as the minimum building unit............................................................................................................... 14
two tricks for building with half studs.........................................................................................................................15

3
studless or studfull?............................................................................................... 17
LEGO evolving.................................................................................................................................................................... 17
studfull building.................................................................................................................................................................18
reinforcing studfull constructions........................................................................................................................ 19
studfull advantages..................................................................................................................................................20
studfull disadvantages............................................................................................................................................20

The Unofficial LEGO Technic Builder's Guide

©2012, Paweł “Sariel” Kmieć
 studless building................................................................................................................................................................20
creating rigid studless connections.....................................................................................................................21
studless advantages.................................................................................................................................................22
studless disadvantages...........................................................................................................................................23
combining the styles.........................................................................................................................................................23
get inspired by Technic sets................................................................................................................................... 24
methods for connecting bricks and beams........................................................................................................27
even vs. odd...............................................................................................................................................................28

4
axles, bushes, and joints......................................................................................... 31
axles......................................................................................................................................................................................31
standard axles...........................................................................................................................................................32
modified axles...........................................................................................................................................................33
flexible axles..............................................................................................................................................................34
bushes.................................................................................................................................................................................. 35
half bush..................................................................................................................................................................... 35
regular bush............................................................................................................................................................... 37
bush with a long pin................................................................................................................................................ 37
universal joints...................................................................................................................................................................38

part II mechanics

5
gears and power transmission basics...................................................................... 43
drivers, followers, and idlers..........................................................................................................................................44
gear ratios........................................................................................................................................................................... 45
efficiency and gears..........................................................................................................................................................46
backlash and gears .......................................................................................................................................................... 47
controlling rotational direction...................................................................................................................................... 47
an inventory of gears.......................................................................................................................................................48
worm gear..................................................................................................................................................................48
8-tooth gear.............................................................................................................................................................. 49
single-bevel 12-tooth gear....................................................................................................................................50
double-bevel 12-tooth gear..................................................................................................................................50
14-tooth gear............................................................................................................................................................50
16-tooth gear............................................................................................................................................................50
16-tooth gear with clutch......................................................................................................................................50
single-bevel 20-tooth gear.................................................................................................................................... 51
single-bevel 20-tooth gear with pin hole.......................................................................................................... 51
double-bevel 20-tooth gear.................................................................................................................................. 51
24-tooth gear............................................................................................................................................................52
24-tooth gear with clutch......................................................................................................................................52
24-tooth gear with crown......................................................................................................................................53
36-tooth gear............................................................................................................................................................53
40-tooth gear............................................................................................................................................................53
differential gears......................................................................................................................................................53

viii contents in detail The Unofficial LEGO Technic Builder's Guide

©2012, Paweł “Sariel” Kmieć
 turntables...................................................................................................................................................................54
knob wheel................................................................................................................................................................. 55
Hailfire Droid wheel gear....................................................................................................................................... 55
obsolete gears...........................................................................................................................................................56

6
chains and pulleys................................................................................................... 57
chains....................................................................................................................................................................................57
pulleys.................................................................................................................................................................................. 59
string and pulley systems............................................................................................................................................... 61
simple pulley system...............................................................................................................................................62
differential pulley system.......................................................................................................................................63
power pulley system................................................................................................................................................ 65

7
levers and linkages................................................................................................. 67
levers.................................................................................................................................................................................... 67
classes of levers........................................................................................................................................................68
from levers to linkages........................................................................................................................................... 69
linkages................................................................................................................................................................................71
Chebyshev linkage....................................................................................................................................................73
Hoeken’s linkage.......................................................................................................................................................73
pantograph.................................................................................................................................................................73
Peaucellier–Lipkin cell............................................................................................................................................. 74
Sarrus linkage........................................................................................................................................................... 74
Scott-Russell linkage...............................................................................................................................................75
scissor linkage...........................................................................................................................................................75
Watt’s linkage............................................................................................................................................................ 76

8
custom mechanical solutions.................................................................................. 77
a stronger differential......................................................................................................................................................77
differential locks................................................................................................................................................................78
a custom differential...................................................................................................................... 79
an axle with a differential lock...................................................................................................... 81
ratchets................................................................................................................................................................................82
linear clutches....................................................................................................................................................................83
eccentric mechanisms......................................................................................................................................................84
Scotch yokes.......................................................................................................................................................................85
a Scotch yoke.................................................................................................................................. 86
Oldham couplings.............................................................................................................................................................. 87
an Oldham coupling........................................................................................................................ 87
Schmidt couplings.............................................................................................................................................................88
stepper motors...................................................................................................................................................................88
Geneva mechanisms.........................................................................................................................................................89
a Geneva mechanism...................................................................................................................... 90
reverse lights......................................................................................................................................................................90
flashing lights.....................................................................................................................................................................91

The Unofficial LEGO Technic Builder's Guide contents in detail ix

©2012, Paweł “Sariel” Kmieć
 turn signals.........................................................................................................................................................................92
complex turn signals...................................................................................................................... 94
double-axle turntable transmission ............................................................................................................................96
a double-axle turntable transmission........................................................................................... 97
a sturdy universal joint................................................................................................................................................. 101
a universal joint............................................................................................................................ 101

9
the LEGO pneumatic system.................................................................................. 103
the Old system................................................................................................................................................................ 103
the New system.............................................................................................................................................................. 104
an inventory of pneumatic parts................................................................................................................................ 105
pneumatic pump (Old).......................................................................................................................................... 105
pneumatic pump (New)........................................................................................................................................ 105
small pneumatic pump (New)............................................................................................................................. 106
distribution block (Old)......................................................................................................................................... 106
valve with studs..................................................................................................................................................... 106
valve with no studs (New)....................................................................................................................................107
large cylinder (Old) ................................................................................................................................................107
6L cylinder (Old) .....................................................................................................................................................107
small cylinder (New) ............................................................................................................................................ 108
large cylinder with square base (New) ........................................................................................................... 108
large cylinder with round base (New) ............................................................................................................. 108
pneumatic tubes and hoses................................................................................................................................ 108
T-piece (Old)............................................................................................................................................................ 109
T-piece (New).......................................................................................................................................................... 110
hose connector with an axle joint (New)......................................................................................................... 110
cylinder bracket...................................................................................................................................................... 110
airtank...................................................................................................................................................................... 111
manometer.............................................................................................................................................................. 112
modding the pneumatic system................................................................................................................................. 112
non-LEGO hoses.................................................................................................................................................... 112
non-LEGO airtanks............................................................................................................................................... 112
removing springs to create motorized compressors................................................................................... 113
pneumatic suspensions........................................................................................................................................ 113
turning your pneumatic system into a hydraulic one.................................................................................. 113

10
pneumatic devices................................................................................................. 115
motorized compressors................................................................................................................................................ 115
a rocking compressor................................................................................................................... 118
motorized valves..............................................................................................................................................................119
autovalve.......................................................................................................................................................................... 120
a motorized valve.........................................................................................................................121
an autovalve.................................................................................................................................. 122
automated pressure switch......................................................................................................................................... 123
pneumatic engines..........................................................................................................................................................124
a single-cylinder engine............................................................................................................... 125

x contents in detail The Unofficial LEGO Technic Builder's Guide

©2012, Paweł “Sariel” Kmieć
a two-cylinder pneumatic engine................................................................................................ 128
a two-cylinder pneumatic engine with sliders............................................................................ 131
builder showcase............................................................................................................................................................ 135
a working water pressure pump................................................................................................................................ 135

11
building strong...................................................................................................... 137
why things fall apart...................................................................................................................................................... 137
finding weak links.................................................................................................................................................. 138
understanding where to reinforce.................................................................................................................... 138
the right way to reinforce............................................................................................................................................. 140
things to remember when reinforcing..............................................................................................................142
reinforced differential casings.................................................................................................................................... 144
four reinforced differential casings ............................................................................................ 145
reinforced worm gear casings.....................................................................................................................................149
three reinforced worm gear casings............................................................................................ 150
load-bearing structures.................................................................................................................................................151
rails, chassis, and body frames...........................................................................................................................151
trusses...................................................................................................................................................................... 154
choosing the right truss....................................................................................................................................... 156
choosing the strongest pieces......................................................................................................................................159

part III motors

12
an inventory of LEGO motors................................................................................ 163
2838, the first 9V motor.............................................................................................................................................. 164
71427, a popular and powerful 9V motor................................................................................................................165
43362, a lighter 9V motor............................................................................................................................................165
47154, a 9V motor in a semitransparent housing................................................................................................ 166
Micromotor....................................................................................................................................................................... 166
NXT motor.........................................................................................................................................................................167
Power Functions E motor..............................................................................................................................................167
Power Functions Medium (M) motor......................................................................................................................... 168
Power Functions L motor............................................................................................................................................. 168
Power Functions XL motor...........................................................................................................................................169
Power Functions Servo motor.....................................................................................................................................169
RC motor............................................................................................................................................................................170

13
LEGO Power Functions system.............................................................................. 171
manually controlling motors .......................................................................................................................................171
remotely controlling motors.........................................................................................................................................172
power supplies.................................................................................................................................................................174
AA battery box........................................................................................................................................................174
AAA battery box......................................................................................................................................................174
rechargeable battery.............................................................................................................................................175

The Unofficial LEGO Technic Builder's Guide contents in detail xi

©2012, Paweł “Sariel” Kmieć
 receiver..............................................................................................................................................................................175
remotes..............................................................................................................................................................................176
basic remote............................................................................................................................................................177
speed control remote............................................................................................................................................177
modifying the remotes...................................................................................................................................................177
a basic remote with steering wheel............................................................................................. 178
a basic remote with sideways lever............................................................................................. 179
a speed control remote with central steering wheel.................................................................. 181
linear actuators............................................................................................................................................................... 183
large linear actuator............................................................................................................................................. 183
small linear actuator............................................................................................................................................. 185
linear actuators vs. pneumatics......................................................................................................................... 185
extension wires............................................................................................................................................................... 186
miscellaneous elements................................................................................................................................................ 187
switch........................................................................................................................................................................ 187
LED lights................................................................................................................................................................ 187

part IV advanced mechanics

14
wheeled steering systems..................................................................................... 191
basic LEGO steering systems.......................................................................................................................................191
return-to-center steering....................................................................................................................................194
Ackermann steering geometry...........................................................................................................................195
a simple steering arm with Ackermann geometry............................................................... 198
convergence of axles.............................................................................................................................................199

15
wheeled suspension systems................................................................................. 203
driven axles...................................................................................................................................................................... 203
suspension systems: concept and categories ........................................................................................................ 204
types of suspensions..................................................................................................................................................... 205
double-wishbone independent suspension ................................................................................................... 206
Tatra-type suspension......................................................................................................................................... 207
pendular suspension............................................................................................................................................. 208
trailing arm suspension (floating axle suspension)...................................................................................... 209
driven and suspended axles........................................................................................................................................ 209
pendular suspension with turntables............................................................................................................... 210
a stabilized pendular suspension..........................................................................................211
portal axles (geared hubs).................................................................................................................................. 213
a stabilized pendular suspension with a portal axle............................................................ 214
a Tatra-type suspension stabilized with four shock absorbers.......................................... 217
an independent suspension................................................................................................... 220
a floating axle with four links............................................................................................... 222
steered and suspended axles...................................................................................................................................... 225
a pendular steered axle......................................................................................................... 225
an independent steered axle................................................................................................. 226

xii contents in detail The Unofficial LEGO Technic Builder's Guide

©2012, Paweł “Sariel” Kmieć
driven, steered, and suspended axles....................................................................................................................... 227
an independent axle ............................................................................................................. 227
a heavy-duty pendular portal axle....................................................................................... 230
a pendular axle with a worm gear........................................................................................ 236

16
tracked vehicles and suspensions.......................................................................... 241
rubber tracks....................................................................................................................................................................241
hard plastic tracks...........................................................................................................................................................242
tracked wheel systems.................................................................................................................................................. 244
suspension systems....................................................................................................................................................... 246
bogies........................................................................................................................................................................ 246
trailing arms suspension with shock absorbers.............................................................................................247
trailing arm suspensions with torsion bars.................................................................................................... 248
experimenting with road wheels.................................................................................................................................249

17
transmissions........................................................................................................ 251
types of transmissions...................................................................................................................................................251
how LEGO transmission driving rings work............................................................................................................ 252
transmission designs..................................................................................................................................................... 254
2-speed synchronized transmission................................................................................................................ 254
2-speed linear heavy-duty transmission........................................................................................................ 254
2-speed RC motor transmission....................................................................................................................... 255
2-speed orbital transmission............................................................................................................................. 255
2-speed ratchet transmission............................................................................................................................ 256
3-speed linear transmission............................................................................................................................... 256
4-speed double-lever transmission................................................................................................................. 257
4-speed synchronized transmission................................................................................................................ 257
5-speed linear transmission............................................................................................................................... 258
10-speed synchronized transmission...............................................................................................................259
continuously variable transmission.................................................................................................................. 260
distribution transmissions............................................................................................................................................ 260
a 2-speed synchronized transmission......................................................................................... 261
a 2-speed linear heavy-duty transmission.................................................................................. 262
a 2-speed RC motor transmission................................................................................................ 264
a 2-speed orbital transmission.................................................................................................... 266
a 2-speed ratchet transmission................................................................................................... 267
a 3-speed linear transmission..................................................................................................... 268
a 4-speed synchronized transmission......................................................................................... 270
a 10-speed synchronized transmission....................................................................................... 271
a continuously variable transmission.......................................................................................... 276

18
adders and subtractors......................................................................................... 277
hard-coupling.................................................................................................................................................................. 277
coupling motors with adders....................................................................................................................................... 277
summing torque with an adder......................................................................................................................... 277
adding more than two motors........................................................................................................................... 280

The Unofficial LEGO Technic Builder's Guide contents in detail xiii

©2012, Paweł “Sariel” Kmieć
 subtractors....................................................................................................................................................................... 280
why use a subtractor?.......................................................................................................................................... 281
longitudinal subtractor......................................................................................................................................... 282
a longitudinal subtractor...................................................................................................... 283
transverse subtractor.......................................................................................................................................... 288
a transverse subtractor........................................................................................................ 289
a studless transverse subtractor......................................................................................... 291

part V models

19
form vs. function.................................................................................................. 295
cars..................................................................................................................................................................................... 295
trucks................................................................................................................................................................................. 296
motorcycles ..................................................................................................................................................................... 299
tracked vehicles............................................................................................................................................................... 299
aircraft............................................................................................................................................................................... 302
planes....................................................................................................................................................................... 302
helicopters............................................................................................................................................................... 302

20
scaling a model .................................................................................................... 307
blueprints.......................................................................................................................................................................... 307
points of reference......................................................................................................................................................... 309
scaling................................................................................................................................................................................ 309

21
the modeling process............................................................................................ 315
size matters..................................................................................................................................................................... 315
wheels............................................................................................................................................................................... 316
other circular elements..................................................................................................................................................319
colors..................................................................................................................................................................................319
devil in the details.......................................................................................................................................................... 320
building at odd angles.......................................................................................................................................... 321
building cleverly .................................................................................................................................................... 323
the next step: controlling your models..................................................................................................................... 323

afterword.............................................................................................................. 325

index..................................................................................................................... 326

updates and additional resources......................................................................... 334

xiv contents in detail The Unofficial LEGO Technic Builder's Guide

©2012, Paweł “Sariel” Kmieć