Skip to content
2064 Docs

3.2.5 - Bumper Construction

3.2.5 - Bumper Construction

Section titled “3.2.5 - Bumper Construction”

The First Line of Defense: Bumpers aren’t just an aesthetic requirement; they are a critical engineering component. A well-built set of bumpers protects our robot, complies with strict FIRST rules, and makes Team 2064 look professional on the field.

Section 1: Core Rules & Purpose Understanding why we build them and the strict rules we must follow.

  • Why Bumpers Matter :material-shield-half-full:

    • Robot Protection: They absorb massive impacts during high-speed collisions, protecting our electronics and mechanisms.
    • Field Protection: They prevent our metal chassis from gouging the field perimeter.
    • Alliance Identification: They clearly display our team number and alliance color to the referees.

  • The “Golden Rules” of Bumpers :material-ruler-square:

Bumpers are heavily scrutinized during Robot Inspection. If our bumpers fail, the robot does not play. Always verify these against the current year’s FRC Game Manual.

:::
* **Wood Backing:** Must be 3/4-inch thick (nominal) plywood.
* **Height:** Typically must be exactly 5 inches tall.
* **Bumper Foam:** Must use approved Foam Profiles (e.g., EPE, EVA, or PE foam).
* **Fabric:** Must be a rugged, smooth cloth (1000 Denier Cordura).
* **Weight Limit:** Entire assembly typically cannot exceed 15 lbs.
  • Team Numbers :material-numeric:
    • Size: At least 4 inches tall with a 1/2-inch stroke.
    • Color: White (or have a white outline).
    • Placement: Clearly visible from all 4 sides of the robot.

Section 2: Materials & Tools Gather everything needed before starting the build. This acts as your official Bill of Materials.

  • :material-forest: Backing & Padding

    Section titled “:material-forest: Backing & Padding”
    • 3/4” Plywood: Cut strictly to 5” height
    • Sheet Metal: Thin sheet metal as a backing (Optional/Replacement)
    • Bumper Foam: Approved profiles for FRC (EPE/EVA/PE)
    • Tape: Gaffer or heavy-duty duct tape

  • :material-texture: Fabric & Fasteners

    Section titled “:material-texture: Fabric & Fasteners”
    • Cordura Fabric: 1000 Denier (Red and Blue)
    • Team Numbers: Iron-on Vinyl Cut out with Vinyl Cutter to FRC Specifications
    • Staples: Heavy-duty 3/8” or 1/2”
    • Adhesive: Wood glue

  • :material-nut: Mounting Hardware

    Section titled “:material-nut: Mounting Hardware”
    • T-Nuts: 1/4-20 size (embedded in the wood)
    • Fasteners: 1/4-20 Bolts or Quick-Release Pins
    • Brackets: Custom aluminum angle brackets (Optional)

  • :material-toolbox: Shop Tools

    Section titled “:material-toolbox: Shop Tools”
    • Cutting: Bandsaw, Table Saw and/or Chop Saw
    • Assembly: Pneumatic/Electric Staple Gun & Cordless Drill
    • Finishing: Iron for Vinyl Numbers & Woodworking Clamps
    • Flat Surface: A large clean work area to assemble bumpers

Section 3: Step-by-Step Construction Measure twice, cut once. Follow these steps in order.

  • 1. The Wood Backing :material-saw-blade:
    • Measure your robot perimeter exactly. Cut the 3/4” plywood into 5-inch tall strips.

Always leave a small tolerance (about 1/8” to 1/4”) between the wood bumper segments and the robot frame so the fabric has room to wrap.

:::

  • 2. Install Mounting Hardware (Do this FIRST!) :material-nut:

    • Do not attach the foam yet. Drill the holes for your mounting brackets and hammer in your T-Nuts on the outside face of the wood.

  • 3. Attach the Bumper Foam :material-tape-measure:

    • Position foam against the wood backing. Use gaffer tape to bind the foam securely.
    • Corners: Miter the ends of the foam at 45-degree angles so they meet perfectly at the corners with no unprotected gaps.

  • 4. Wrap the Fabric & Iron on Numbers :material-iron:

    1. Lay fabric face-down. Pull fabric tightly over the foam to the back of the wood.
    2. Tape the center first, pulling the fabric taut as you move outward.
    3. Use duct tape to set fabric to backing temporarily so it doesn’t shift.
    4. Mark center location for number alignment with a LIGHT pencil line only.
    5. The Corners: Treat them like wrapping a present. Fold neatly, avoid bulging, and staple heavily.
    6. Mark all center lines of where numbers will be placed on all bumper sets.
    7. Dry fit numbers to ensure perfect alignment (Do not iron yet).
    8. Set up iron and press onto fabric (Note: See separate tutorial for ironing).
    9. Let cool completely.
    10. Remove plastic backing when cooled down. Repeat for all sides.

Section 4: Mounting Strategies How we attach them to the chassis is just as important as how we build them.