So now we've got a nice little pile of parts, let's get some assembly done!
The manual says to start with the yaw axle, so grab 2 "Axle holders" from your delrin pile and 1 "Yaw Axle" from the hardware bag:
From there it says you want to use an exacto knife to put a chamfer on the inside edge of one of the holes. That seems a little clumsy to me, and I chose to use a drill bit to do the job. I imagine they want people using a knife to absolutely preclude the possibility they will just ream out the hole accidentally instead of adding a chamfer. So note here, DO NOT USE A DRILL BIT TO REAM OUT THE HOLE. It is supposed to be a
very tight fit.
The "Yaw Axle" itself is 3.1mm OD, so I chose to use a 5/32 drill bit which measures out to 3.9mm OD. Holding the bit with just my fingers I very lightly pressed the bit against the Axle Holder and spun the bit a few times to create a very small chamfer (beveled edge) on the inside edge as seen here. This literally took two seconds and a very light spin, don't get carried away here!
Now take the Yaw Axle and place it against the chamfer with your hands, keeping it at a 90* angle to the Axle Holder. With a small hammer slowly tap the axle into the Axle Holder. It helps to have a surface underneath that will give a little and let the axle penetrate out the other end allowing it to "cut" it's way through the Axle Holder. If you hammer against a hard surface you will notice that the Yaw Axle pushes some delrin out the other end and stops once it binds up against the surface as the excess has nowhere to go. You might also need to scrape some of this excess off the end once the Yaw Axle has pushed through to clean it up. Repeat the process so it looks like this.
Grab an 1/8″ Axle Collar from the hardware bag. Note that in my kit, all the little black set screws for the Axle Collars were loose in the bag and I had to hunt for them. Put a dab of loctite on the set screw and screw it part way into the Axle Collar. Leave about 1" of the Yaw Axle protruding through the Axle Holder, and slip the Axle Collar onto the Yaw Axle. With the Yaw Axle up against something like the edge of the work bench (so the Collar doesn't slip off) slowly push the Axle Holder towards the end of the Yaw Axle until only about .5mm of the Yaw Axle is showing through the Axle Collar. Making sure the Axle Collar is firmly against the Axle Holder, tighten the set screw.
Take the Yaw Bottom Plate (part G above, three holes) and spacing the "other" Axle Holder as needed, assemble the Axle Holders into the Yaw Bottom Plate leaving one hole in between the two Axle Holders. Then take the Yaw Top Plate and slip it onto the assembly. It should look like this when done.
Get the Yaw Side Plate (L shaped) and your Servo Bracket. Take the Yaw Side Plate and lay it flat on the bench so that the two centered holes are to your left and the part with the two centered rectangles is facing down towards you. Take the Yaw Axle assembly and insert it down into the Yaw Side Plate making sure that the side with the third hole (part G above) faces down towards you.
Take the Servo Bracket, and with it orientated so that the "hooks" face up away from you insert with two motions. #1 slip it into the two rectangle slots in the Yaw Side Plate. #2 very slowly and carefully slide the Servo Bracket upwards into the Yaw Axle assembly. BE CAREFUL! This piece takes finesse to get inserted, not force. If it does not slip up/in, very easily bend the assembly around until the holes line up and it goes in. Again, this does not take any force, if you have to use force it's not lined up correctly. Be patient.
Next take the Yaw Top Plate and cap off the assembly, and slip the 1/4 ” nylon spacer onto the axle.
Your Yaw Axle housing is now complete!