Robot Wars: The Constructor's Guide

Robot Wars: The Constructor's Guide (erroneously captioned as The Constructors Guide on-screen) was a bonus featurette that appeared at the end of the original UK VHS release of Robot Wars: The First Great War, serving as a robot building guide presented by Craig Charles. The majority of the featurette was filmed at the now-closed BBC Visual Effects Department on Kendal Avenue in West London, with additional footage filmed in the workshops of featured roboteers.

Synopsis[]

RWCGintro — Craig Charles introduces the featurette

"Welcome to the BBC's Visual Effects department, rumoured to be the birthplace of Matilda, Sergeant Bash, Shunt, Dead Metal and Sir Killalot. There is no better place on Earth to introduce you to the art of building robots. Come with me."

— Craig Charles introduces The Constructor's Guide, outside the design workshop of the BBC Visual Effects department

Set mostly within the BBC's Visual Effects department on Kendal Avenue, Park Royal in West London, itself the birthplace of the House Robots, The Constructor's Guide takes a look at the various stages of constructing combat robots. Whilst not, as explained by Charles, a definitive guide to building robots, the featurette offers aspiring roboteers tips and advice from Technical Consultants Derek Foxwell and Mat Irvine, as well as some of the roboteers who competed in The Second Wars. Explanations of robot components (e.g. radio control equipment, motors, batteries, failsafes) and the Robot Wars rules are also given, the latter for guidance.

"This is not a definitive guide to building a robot, but what we can do is take you through the various stages of construction. We can talk to the roboteers themselves and give you some advice on what does and doesn't work. For instance, cornflake packets - notoriously bad robots. Okay, you wanna build a robot, what do you have to do? Well, if like me, you don't know one servo from another, then don't even think about starting. But if you already got a half-decent grasp of electronics, engineering and radio-control modelling, then you're already on the way to being a roboteer. Anyway, before we go into detail, let's start at the beginning."

— Craig Charles

Segments[]

What is a Robot?[]

RWCGrobotfoxwell — Derek Foxwell talking Craig Charles through the essentials of fighting robots

"Well, we all know what robots look like in science-fiction films. We've all seen my mate Kryten, for instance. But in the terms of Robot Wars, what do we actually mean by a robot?"

— Craig Charles

Charles introduces the segment and interviews Derek Foxwell about the basic principles of a robot. Foxwell explains that a robot can be "any radio-controlled fighting vehicle", even speculating that they can be autonomous - an incoming data graphic scrolls across the screen at this point describing autonomous robots in more detail. Foxwell also estimates that a typical robot could be built in anywhere between one week and three months, and for as little as £100-150 depending on the use of scrap parts.

RWCGrobotirvine — Mat Irvine lists the key weight classes for Robot Wars

Charles then speaks to Mat Irvine, who talks about the various weight classes run in the earlier UK Series. Heavyweights are first mentioned as the primary and "biggest" class, with featherweight, lightweight, and middleweight categories also being briefly discussed. At this point, a second incoming data graphic scrolls across the screen outlining these classes in more detail. Irvine then introduces First Wars competitor Demolisher - presented by Foxwell - as "one we made earlier" and also as the reigning featherweight champion. He also explains that a featherweight like Demolisher can be converted from a radio-controlled car - such as the unmodified one also presented - and built for as little as £50.

Health and Safety[]

"Well, Robot Wars is all about creativity, ingenuity and teamwork. It's not about chopping your fingers off. So, put your chainsaw down and listen up."

— Craig Charles

RWCGcassiuspin — Rex Garrod demonstrasting Cassius' safety pin

The segment begins with Simon Scott from Team Razer and Rex Garrod from Team Cassius emphasising the need for appropriate safety precautions and equipment when maintaining and operating combat robots. Examples include the use of safety goggles and ear protection during the build stage. Garrod uses his speaking piece to highlight the steel locking pin for Cassius' flipping arm, which is used to prevent the weapon from accidentally firing when not in use. Garrod stresses the "really dangerous" nature of combat robots, warning that the consequences of someone getting hit by Cassius' flipper can be "fatal." As such, he refused to operate his robot's pneumatic weaponry when demonstrating it at local school and college events.

Razer failsafe — Razer's failsafe unit (top, bottom-right) and microswitch (bottom)

Team Razer's segment focused on the failsafe systems installed on their eponymous machine. Scott highlighted both the failsafe unit - costing £15 - and microswitch components, the functions of which were then described by Ian Lewis. Lewis emphasised the microswitch - operating from the robot's cam mechanism - as being especially important, allowing Razer to become immobilised in the event that it lost its radio signal. A clip of Razer pinning and crushing down on Inquisitor (Series 2, Heat D, Arena Semi-Final) is shown to illustrate the possibility of it otherwise going out of control, as Lewis then says he's going off to squeeze somebody.

"...the microswitch shuts the whole system down. It's linked up to the speed controllers and it cuts the supply voltage to them, and stops the machine clearing off under its own steam. As soon as it loses the signal from the transmitter, as soon as that's lost... the machine shuts down completely dead."

— Ian Lewis explains the microswitch used as part of Razer's failsafe setup

Rules and Regulations[]

In this segment, Charles - wearing a welding helmet - gave a brief summary of some of the show's rules and guidelines:

"Rules and regulations govern every aspect of Robot Wars. Many of them are concerned with health and safety issues - what weapons you can have, what weapons you can't, weight limits and so on. For instance, you might like to arm your robot with a dirty great flamethrower like Sgt. Bash, but for your own safety, you can't. A full list of the rules and regulations will be issued to you on joining the Robot Wars Club and completing the necessary application forms. But in case you want to know what you're letting yourself in for, here's uh... a brief summary."

— Craig Charles

Safety Restrictions

All explosives, corrosives, flames and pyrotechnics are prohibited

Untethered projectiles are prohibited

Compressed gas is limited to 1000 PSI

Hydraulic fluid is limited to 3000 PSI

Other Restrictions
The following materials and practices are prohibited

Radio jamming

Electronic weaponry - Stun guns, Tesla coils, etc.

Liquid weaponry - Water, oil, glue, etc.

Gas-based weaponry - Expandable foam, neon, etc.

Power

Fuel or Electric

Fuel capacity limited to the lesser of 8oz (fluid ounces) or 6 minutes operating time

Fuel tanks must be adequately protected against penetration

The above rules were followed by an additional spiel highlighting technical and safety checks, along with the potential for disqualification in case of rule breaches.

"Robots will be inspected for safety and reliability before being allowed to compete. Tethers, blades, arms, levers, air cylinders and all other mechanical parts and weaponry must be strong and secure. The organizers reserve the right to disqualify any entry at their discretion. And please note, all rules and guidelines are subject to change - contestants who fail to adhere to rules and guidelines may be subject to disqualification. And please remember, do not start building a robot until you have been officially asked to by us."

— Craig Charles

Design[]

"So, now you know the rules. You're ready to build your very own galvanized gladiator. And it goes without saying, that you're gonna be very careful, aren't ya? Yes you are, missus. Before you start tinkering with the lawnmower, it's time to put pen to paper."

— Craig Charles

Razer design sketches — Design sketches of Razer

Simon Scott begins the segment by showing some of the initial design sketches for Razer, where the design centred on weaponry that would have destroyed the robots they had seen in the previous series. Scott mentions that he and Lewis had considered angle grinders, but they would not have provided the "mass destruction" he was after. Ian Lewis mentions how robots are often designed with mobility first and weaponry second, whereas Razer was planned around the weapon, how it could immobilise opponents, and how it could be moved around the arena.

Mortis builders guide — Arthur Chilcott explains the importance of design in Mortis' entry

Arthur Chilcott of Random Violence Technologies also stresses the importance of a robot's design, estimating that of the 3,000 hours spent on Mortis, around 1,000 of those were on the design. Chilcott mentions that the design was based around the materials available to him and his team, rather than drawing something and then looking for what could be used for construction.

Rex Garrod discusses how Cassius was first built as a "really rough prototype" made of plywood sheet. Garrod felt that it was important to build a physical "mockup" before making any design drawings, the arrangement providing him with a better idea of the robot's planned design parameters and internal layout.

Radio Control[]

"Of course, you might have designed a future Robot Wars champion on paper, but a basic understanding of radio-control technology is essential if you're gonna bring it to life. And don't get me wrong, autonomous robots capable of doing their own dirty work are allowed on Robot Wars. But for the moment, let's stick with one of these."

— Craig Charles, as he shows a radio controller to the audience

RWCGradiocontrol — Derek Foxwell explaining radio control equipment

Charles begins the segment with Derek Foxwell, asking about controllers, transmitters and radio frequencies. To make the segment as easy to understand for viewers not inclined with radio control terminology, he humorously suggests to Foxwell: "talk to me as if I'm an idiot."

Foxwell, showing a basic transmitter, outlines the frequency of 40MHz -the only band the organisers can allow- and the interchangeable crystals used in said transmitters. During this, an incoming data graphic scrolls across the screen highlighting the former along with additional frequencies of 27MHz and 35MHz, both of which the organisers strongly advise against using. Foxwell also notes that, in the official regulations, it is strongly recommended that roboteers bring spare crystals with them to avoid "clashes" with other frequencies.

Foxwell mentions that radio controllers are available off-the-shelf from most good hobby shops, ranging from £100-150.

Robot Components[]

"Of course, radio-control gear is pretty useless, unless you got something to actually control. And that something is obviously your robot. Now, it's not unusual for robots to end life scattered into a thousand pieces across the arena floor, but they start out life as two pieces: the body and the chassis. Now, of course, the body protects the robot, but it's what's inside that ultimately counts. So, let's have a peek under the bonnet."

— Craig Charles

Mat Irvine leads the segment discussing each component in detail.

Speed Controllers[]

RWCGspeedcontrol — Ian Lewis shows Razer's speed controller configuration

Irvine explains how electrical power from the battery runs through to the speed controllers, and how they support the motors supplying power to the independently-driven wheels. During this, an incoming data graphic scrolls across the screen explaining that new club members, upon completing the required entry forms, will recieve a list of suppliers and recommended manufacturers for robot components. The functionality of speed controllers is concisely explained; their purpose is to maintain smooth power transitions. However, Irvine notes that, in instances where the motors stall (such as when fighting something as heavy as Sergeant Bash, or getting pushed into a corner by Sir Killalot), extra power drawn from the batteries can cause them to start getting "hot". In this context, he adds that speed controllers from a radio-controlled car would not be suitable for a heavyweight robot due to overheating. To counter this problem, he instead presents a more appropriate speed controller that is approximately the size of his hand.

Ian Lewis from Team Razer also comments on the necessary size of speed controllers, adding that it depends on the amount of power required by the chosen motors. Variants for radio-controlled cars were again discouraged from use in heavyweight robots. In Razer's case, its large speed controllers and caddy motors were rated to a maximum of 100 amps, with a continuous draw of 50 amps in regular operation. However, they still required cooling fans to prevent them from overheating, one of which is also presented by Lewis.

Arthur Chilcott discussed how important speed controllers are for a robot's mobility, in comparison to a purely "switch"-based control system. He notes that without the former, a robot is likely to only be able to move in a straight line, and would not be able to approach another robot in a smooth, controlled manner.

Motors[]

RWCGmotor — Derek Foxwell explains various power options

On the robot Irvine uses as the example in the previous segment, he explains how each wheel is powered by a separate motor. Derek Foxwell leads this segment talking about the main propulsion methods - the internal combustion (petrol) engine and the electric motor. Foxwell discusses some of the more common motors available and their various pros and cons, such as:

Motorcyle starter motors, which are powerful but "extremely difficult to reverse", so Foxwell recommends avoiding them.
Car starter motors, which also have a lot of power but would require a gearbox to allow a robot to move backwards.
Foxwell mentions a 12V DC motor and how useful they can be for powering weapons.
Foxwell shows a starter motor from a model aeroplane, which is both cheap and powerful.
The Sinclair C5 motor is last to be shown; Foxwell comments on its popularity due to it being inexpensive and relatively efficient.

Arthur Chilcott shows off a 900W compound series wound motor used in Mortis' axe. Despite its age and weight (about 6½kg), the motor provides plenty of power, the main trade-offs that Random Violence Technologies had chosen to make in developing their machine's weaponry. Rex Garrod talks through the compact 12V "power" motor for Cassius, which is run on 24V. To prevent overheating issues, Garrod explains that the voltage is pulsed through the motor itself.

Simon Scott discusses how Razer is powered by electric 12V caddy motors, also uprated to 24V, as they were the only motors light enough given the weight of the weapon and chassis. Hydraulic and petrol motors were also considered, but ruled out due to the aforementioned weight constraints. Ian Lewis also notes how it made sense to continue with electric motors for the drive, as a similar "pump" motor was used in Razer's weapon system. Thus, it did not make sense for the team to adopt two different systems, when everything could be used together as one system. Two battery packs were used to power Razer's systems - voltages were 24V for drive and the standard 12V for the weapon "pump".

Batteries[]

RWCGbattery — Foxwell and Irvine explaining the advantage of lead acid batteries

Mat Irvine and Derek Foxwell talk through two of the most prevalent battery types for electric-powered robots in the Classic series - NiCad and lead acid. Irvine discusses how NiCad batteries already feature in radio control systems and transmitters, but would only be suitable for powering featherweight and lightweight robots by this early point in the show's run. For middleweight and heavyweight robots, Irvine recommends using lead acid batteries. Foxwell explains that the lead acid batteries used in robots do not contain liquid; leakage cannot occur during simple collisions.

RWCGmortisbattery — Arthur Chilcott comparing batteries

Arthur Chilcott and Ben Impey show two of the small batteries used in Mortis - a total of six 5 amp types are used in place of a single bigger pack of comparable capacity. The main advantage of using smaller batteries is emphasised; they can be put into different places inside the robot while maintaining a similar power output.

Simon Scott also shows the larger lead acid battery used to power Razer, and Rex Garrod shows the special aircraft starter battery used inside Cassius. Garrod explains that the low internal resistance of these batteries allows for them to "dump" a large amount of current in a short time. This results in faster acceleration - an advantage Garrod was satisfied with despite their higher cost.

Ian Lewis stresses the benefit of buying new batteries rather than hunting for them in rubbish tips and scrapyards, based on his initial experience trying to find second-hand examples. The main disadvantages of the latter are highlighted as depleted capacity, excessive heat and reduced functionality. The lead acid type used in Razer was not particularly expensive - costing only £30 - and would provide plenty of power for the duration of the battle without overheating.

Bodywork[]

Charles begins this segment asking Mat Irvine about appropriate bodywork materials - for chassis and armour - to use when building a robot. Irvine notes how metal might seem "a logical choice", but mentions how wood might also be useful. Among the potential advantages of the latter from a build perspective include being easier to work with and easier to cut through. Irvine adds that wood could potentially "jam" cutting weapons such as a circular saw. Composite fibre materials such as fibreglass and Kevlar are also mentioned; Irvine suggests that the former is ideal for more complex shapes, which can be moulded using resins.

Charles asks Foxwell about aesthetics and painting. Foxwell emphasises the need for Robot Wars to showcase "visually effective" machines; thus, he recommends that competing robots should "look very mean", while also being "nicely decorated" and "attractive" for competition.

Weapons[]

"So, the chassis' nice and strong, the motor's up and running. It looks beautiful, but what about the cutting edge? What about the weapons?"

— Craig Charles

Irvine talks through four of the main weapon categories adopted by teams in earlier UK Series - spikes, lifting devices, pick axes and rotating devices. An example of a pneumatic spike is manually demonstrated, while clips of G.B.H.'s victory over Talos (Series 2, Heat J, Arena Semi-Final) and Mortis' attacks on Matilda in its first Series 2 Gauntlet run are shown to illustrate the latter types.

RWCGcassiusram — Rex Garrod demonstrating Cassius' weapon

Arthur Chilcott demonstrates the full motion of Mortis' axe - the weapon's third iteration - while noting it to be difficult to design, build and work properly. Keeping himself away from his machine's front end, Rex Garrod demonstrates both Cassius' pneumatic suspension and flipping arm. The former allows Cassius to drop its front wedge shape to ground level, in turn allowing the whole robot to get underneath opponents more easily. Garrod explains that the flipping arm is purposefully power-restricted to prevent the robot "destroying itself" with an unloaded flip. A clip from the Series 2, Heat H final, where Cassius flicks Matilda onto her side, is shown as part of this sequence.

Concerning Razer, Simon Scott reiterates once again how design and functionality were important for its crushing weapon. More footage of its battle against Inquisitor is shown as Scott explains a few key functions and statistics, including a force of nine tonnes from the ram and an operating pressure of 3,000psi.

RWCGsodastream — Derek Foxwell explaining how SodaStream bottles can be used

Derek Foxwell shows off a SodaStream bottle, explaining its use in powering the pneumatic scoop on Behemoth. Footage of Behemoth firing the weapon during its first Gauntlet run is shown, as the apparent simplicity of a pneumatic system is briefly addressed. Foxwell then shows a car starter motor and how it can be used to operate a pickaxe. A reference to the flywheel-driven weapon on Killertron leads into footage of it striking Shunt, during its Gauntlet run from Series 2, Heat E.

"Other devices" mentioned by Foxwell include systems powered by hydraulics, though their "complicated" nature leads him to advise less experienced competitors to avoid those in particular.

Driving[]

"Well, your weapons are attached, your robot's looking mighty mean. But it's no good having a decent robot, unless you got a decent robot driver."

— Craig Charles

Charles introduces this segment by asking Derek Foxwell about what makes a good robot driver. Foxwell simply replies "practice", and how an appealing robot could be undermined by improper driving skills.

Ian Lewis notes his own experience racing remote-controlled cars, but that controlling the larger and heavier Razer is not quite the same. To prepare for sudden and unexpected movements in competition, he emphasises the need to "practice big time" to get acclimatised and comfortable with controlling a fighting robot.

And Finally...[]

This segment gave personal advice from the featured roboteers regarding the experience of building robots.

Rex Garrod's main tip was for roboteers to make a "comfortable" workplace for themselves. Adequate lighting and heating were stressed as important features, along with a nearby radio for listening to music. Garrod felt that an ideal working area would have to be just as, if not more, homely and relaxing than a living room or lounge.

Ian Lewis warns of weight being a major "pitfall" for competitors. Not monitoring the robot's weight - within the confines of the class limits - could risk roboteers having to "rob" certain capabilities from their machines prior to competing. Simon Scott recommends weighing components as they are found and added, as failing to do so could result in less satisfactory robot designs and/or weaponry. Both then promote the idea of designing the weapon first and how that should take precedence over other factors. A "really good" build is mentioned as potentially being in contention for accolades such as the Best Design Award; Razer's Series 2 trophy is used to illustrate Lewis and Scott's point.

Arthur Chilcott stresses planning as the most important part of the build process, above everything else. He recommends setting out plans for every aspect, so as to not spend excess money on parts which may not be useable.

Summary[]

This segment provided a brief summary of every subject that had been covered up to this point. Video diary footage submitted by competitors - including clips televised in Robot Wars Revealed - were played in the background as Craig Charles explained each of the given steps:

"Well, that's almost all we've got time for. Hopefully, this step-by-step guide to building your own metal monster has set you well and truly on the road to becoming a roboteer. But before we go and in traditional school teacher style, here's a brief summary. No talking at the back!"

— Craig Charles

1. Join Robot Wars Club - "Firstly, join the Robot Wars Club to receive necessary application forms, technical advice, health-and-safety guidelines, and rules and regulations."

2. Discuss and Design - "Secondly, before you start juggling with chainsaws and welding scrap metal together, give a lot of thought to the type of robot you want to build. Talk it through with your teammates and then, design your robot on paper."

3. Find Your Components - "Next, start collecting the necessary components - radio-control gear, batteries, speed controllers, motors, armour and weapons. Use your initiative - scour scrapyards, salvage materials and generally, scavenge. If you want to build a heavyweight robot, don't rely on off-the-shelf components normally used in radio-control modelling."

4. Build Safely - "Then, start building your robot, safely and carefully. If you're uncertain about some aspect of designing, constructing and operating a robot, don't even start. And if you're under the age of 18, you must involve a responsible adult."

5. Practice Driving - "Finally, once your robot is up and running, practice, practice, practice. Driving skills are very often forgotten, but are essential for victory in Robot Wars."

"So there you have it, an introduction to the noble sport of Robot Wars. If this A to Z of do's and don'ts to building your own mechanized warrior has inspired you, then, um... hey, why not give it a go?"

— Craig Charles

This was followed by a variation of the Robot Wars Club promotion from near the end of The First Great War with nearly the same narration dialogue, except with Charles stressing once again the importance of seeking help from responsible adults if the competitor is under the age of 18 after mentioning again the dangers of building combat robots. The "Information Hotline" number was substituted by the web address for the original Robot Wars UK website.

"So there you have it. Thanks for watching. And remember; join the Club, join the cause. Build a robot, for Robot Wars"

— Craig Charles' sign-off