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3.2.5 - Bumper Construction

The first line of defense. Bumpers protect the robot, meet FIRST rules, and show team number and alliance color. Build them to the current Game Manual, not last year’s noodle method.

Core rules

Section titled “Core rules”

Bumpers absorb collisions, keep the frame off the field perimeter, and identify the alliance. They are an inspection item. If they fail, the robot does not play.

2026 padding (R402):

  • At least 2.25 in deep and 4.5 in tall
  • Solid blocks, sheets, or stacked rods
  • Solid pool noodle or backer rod
  • Closed-cell polyethylene, including crosslinked, 1.5–3 lb/ft³
  • EVA closed-cell foam, 2–6 lb/ft³
  • Foam floor tiles
  • Mixed layers are allowed in one bumper

Also:

  • Wood backing is 3/4 in nominal plywood and must support the pad
  • Cloth is a rugged smooth fabric, commonly 1000 denier Cordura
  • Hard parts may not extend more than 1.25 in past the robot perimeter, and foam must cover them by at least 2 in
  • Each corner is filled with uncompressed foam for at least 2.25 in, with no gap
  • The bumper zone, 2.5 in to 5.75 in off the floor, must be filled with supported padding
  • Numbers are at least 4 in tall, 1/2 in stroke, white or white outline, visible from all four sides

Materials and tools

Section titled “Materials and tools”

Backing

  • 3/4 in plywood, at least 4.5 in tall
  • Must support the full depth of the foam

Padding

  • Default: stacked foam floor tiles, or crosslinked polyethylene sheet
  • Solid pool noodle or backer rod is a backup
  • Hollow noodles are not legal
  • Minimum stack is 2.25 in deep

Cover and fasteners

  • 1000 denier Cordura, red and blue
  • Iron-on vinyl numbers, cut to the manual size
  • Staples into the wood, tape to hold the pad
  • Soft fasteners only outside the hard-part limit

Mounting and tools

  • 1/4-20 T-nuts, bolts, or ball-lock pins
  • Saw, drill, staple gun, iron, clamps
  • A clean assembly surface

Construction

Section titled “Construction”

Build a solid pad, not a noodle wrap.

1. Wood backing. Measure the robot perimeter. Cut 3/4 in plywood to at least 4.5 in tall. Leave about 1/8 in to 1/4 in of clearance to the frame so the cloth can wrap.

2. Mounting hardware, before the foam. Drill and set T-nuts on the robot face of the wood. Nothing hard may stick out past the foam.

3. Build the pad. Stack tiles or sheets to at least 2.25 in. Glue or tape the stack to itself, then to the wood. If you use solid noodle, pack the rods so there is no tunnel down the bumper. Do not use a hollow noodle.

4. Corners. Fill each corner with uncompressed foam for at least 2.25 in from the corner. A 45-degree cut is fine only if the joint is solid foam with no gap.

5. Cloth and numbers.

  1. Lay the cloth face-down and pull it tight over the pad onto the back of the wood.
  2. Tape the center first, then pull outward.
  3. Hold it with tape so it cannot shift, then staple to the wood.
  4. Mark number centers with a light pencil line.
  5. Fold corners flat, like a wrapped package, and staple them.
  6. Dry-fit the numbers. Do not iron yet.
  7. Press with the iron, using the ironing tutorial for temperature and dwell.
  8. Let them cool, peel the backing, and repeat for the other sides.

Mounting

Section titled “Mounting”