Take the base template piece and cut it out. Place a piece of dowel horizontally across the template. Starting from the shortest edge, use the craft knife to cut the dowel roughly to length and glue them together with PVA. Stop at the hatched section, and then cut away any excess dowel to follow the shape of the template.
Design Challenge Extraordinaire: The Dwarf Design Project: A Multi Person Vehicle About the Extraordinaire The Dwarf lives in underground caverns amongst fellow dwarves. They must all work together to provide safety and comfort for their society. Our Extraordinaire is an inventor and an engineer. He is inspired by biomimicry and strives to make contraptions which helps his community. There isn’t any electricity in the Dwarf’s world, he must build everything from metal, wood, leather and gemstones. Without motors or engines, the dwarf must innovate to create automated or mechanical gadgets. Design Solution: The Shuttle Bug
Dwarf A Multi Person Vehicle
Materials • • • • • • • • • •
Cardboard Scissors Craft Knife 0.1 inch Square Dowel Hot Glue Gun PVA Glue Grey Paint Paper Masking Tape Print out of template
• Maker Studio parts: • 2 Medium Gears • 1 Small Gear • 6 Long Connectors • 1 Medium Connector • 8 Short Connectors • 8 1.5 inch Rods • 2 4.25 inch Rods • 2 5.5 inch Rods • 1 7 inch Rod • Lots of Hub Caps! 1
DESIGN STUDIO Procedure 1. Take the base template piece and cut it out. Place a piece of dowel horizontally across the template. Starting from the shortest edge, use the craft knife to cut the dowel roughly to length and glue them together with PVA. Stop at the hatched section, and then cut away any excess dowel to follow the shape of the template. Cutting the dowel to be slightly longer than you need will help to create the right shape. You can use the template to mark out the excess and cut away to make a nice curve. Don’t forget to use a cutting mat! It will protect your table, and help your blade stay sharper for longer. 2. Use the same template to cut out the full shape in cardboard, ignoring the hatched section. Take a second piece of cardboard and cut out two rectangles, 1 inch by 5.5 inches. 3. Place the long edge of the rectangles along the centre (running from flat edge to flat edge) of the base. Move each rectangle out half an inch and use the hot glue gun to stick them in place. These are your rod supports for the upcoming steps. 4. Slide one of your medium gears onto the 7 inch rod and secure it with some hub caps. The feet of the hub caps should slot into the gear. 5. With a single layer of masking tape, join the two 4.25 inch rods together, and the 5.5 inch rods to create an 8.5 inch rod and an 11 inch rod. Slide the small gear to the join in the centre of the 8.5 inch rod, and secure it with some hub caps. Slide your second medium gear into the centre of the 11 inch rod and secure it with some hub caps. All of these hub caps should slot into the gears. You should be able to place these gears onto the rectangles you glued onto the base earlier, so that the gears don’t touch the base. If they do, either use a craft knife to remove the rectangles and replace them with taller ones, or simply add more cardboard to the top with a glue gun. 6. Take one of the short connectors and attach it to the left side of the 7 inch rod with hub caps, making sure the feet go into the connector. Place this rod on the rectangles, with the connector facing the long edge of the base. Position the connector so it is just slightly off from the edge of the base and mark that spot. 7. Cut out 12 small squares measuring roughly 5/8 inches. Take 4 of them and cut a small slit near the edge of each of them. Slot these onto the rod supports both sides of the 7 inch rod and glue them in place. Make sure when you are gluing these squares in place that they don’t interfere with the cogs or hub caps. If they touch, it could affect how the mechanism works. 8. Place the small gear against the medium gear and repeat step 7. 9. Place the second medium gear against the small gear and repeat step 7. 10. Cut out some small rectangles to be placed between the two wedges, on top of the rods, and glue them over the rods. 11. Create a cardboard rectangle measuring 4.5 inches by 2.5 inches and use a hot glue gun to attach the long edge of the rectangle to the front edge of the cardboard base. Make a second rectangle measuring 3 inches by 2.5 inches and use a hot glue gun to attach the long edge to the back edge of the cardboard base.
DESIGN STUDIO 12. Cut out 8 cardboard rectangles measuring 2.5 inches by 1 inch. Using the glue gun, attach the short edge of the rectangles to the base either side of the rods and on the corners, adjacent to the cardboard you attached in step 11. 13. Take the Front template, after cutting out the hatched section and lay dowel on top of the template vertically. Cut the dowel roughly to length and glue together. Once the glue is dry cut away the excess dowel. 14. After removing the hatched section in the Back template, use the unhatched section to make a cardboard piece, and the hatched section to create a dowel piece and use the glue gun to stick the two together. in place, and then secure the square from step 9 to the cardboard strip. 15. Take another one of the small connectors and one of the 1.5 inch rods. Slide the rod into the last hole in the short connector which you attached in step 6 and through the second small connector, so that the second connector stands vertically. Secure this with hub caps, making sure the feet of the caps turn out – not into the connectors. 16. Take the base template and cut out the hatch section. Check that the dowel base fits on top of the cardboard struts, and doesn’t interfere with the connectors. Once you’re confident that there’s no interference, use the template to finish the base – making sure to leave a gap where the hatching was. 17. Once you’re confident your dowel base fits, glue it in place, making sure the small vertical connector goes through the hole in your base. Optional: you can use paper and PVA to create benches for the dwarves to sit on! If you make benches, consider how much space it would take for a dwarf to comfortably sit down? Or to move around the inside of the Shuttle Bug. 18. Cut out a rectangle of paper roughly an inch thick, and 2 inches wide. Use PVA to glue this to the front of the back panel, and to the cardboard strut, at the back of the Shuttle Bug, (the smallest flat edge). 19. Use PVA to glue the front panel to the front of the Shuttle Bug, (the larger flat edge), and wait for the glue to dry. 20. Take the medium connector and another 1.5 inch rod and connect the short vertical connector to the second hole in the medium connector. The hub cap feet should face in to the small connector, and outwards away from the medium connector. 21. Cut 3 pieces of dowel to 1.5 inches and glue them together. Repeat this step so you have 2 struts. Wait for these to dry. The next objective is to use these struts to make a support, so that you can use the medium connector in a pump fashion to rotate the gears backwards and forwards. 22. Place one of the struts behind the medium connector, around the 4th hole, and mark the centre. Cut out a 0.25 inch piece of dowel and glue it to this mark. Once the glue has dried, place the two 1.5 inch struts either side of the medium strut, so the small dowel piece goes through the hole and glues to the other strut. 23. Glue a piece of paper to the top of the Shuttle Bug, leaving a slight over hang over the front of the Shuttle, and cut away any excess.
DESIGN STUDIO 24. Paint all the cardboard and paper parts of the Shuttle Bug grey. The cardboard and paper represent the metal parts of the vehicle! 25. To put the legs together, take a short connector, a 1.5 inch rod and a long connector, attaching the three together with the hub cap feet facing into the connectors. Do this 6 times. 26. Make sure the connectors are at right angles to each other, and attach them to the long rods with the hub cap feet pointing towards the connectors. 27. Finally use a glue gun to create small “crystals” on the front of the Shuttle Bug to light the way. Finished!