Just a quick suggestion. I think the servo Calibration instructions should come before the assembly instructions in the tutorials. I just got a new Six from Brookstone, and because I have some experience, I calibrated the servos before starting assembly. It is a good thing because one of them was off by 90 degrees (and most were off by one or two gear teeth, nothing that a servo profile couldn't have fixed). Also a good thing because I discovered that the 20 amp fuse inside the body was missing....
I then went through the tutorial, even though I have done it before and am experienced with EZ-B robots, this is my first Six. I noticed that the assembly instructions were before the calibration instructions. If I had assembled first and then discovered that one of the servos was badly out of calibration, it would have been frustrating. Since I calibrated first, it was no big deal.
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Probably better to handle the one off issues than put the calibration instructions up front and maybe scare away the casual user.
With the few thousand units we ship per month of robots, there's bound to be some quality issues. Just sucks when they're concentrated in some of the community members.
It's something we, and every company are working to address - to what cost? That's the question. Throw more money at it merely increases the cost of the product. So if less than 1% of issues occur, that's way more cost effective than increasing pricing and delays for the less than 1%.
Well, just another joy of owning a company