Making scale models from Card boards is a passion for me since child hood, Got inspired from my father when he gifted me a scale model. It gave me a idea to make more accurate shapes of models. Thus inspired to make me a mechanical engineer graduate.
Card boards are getting waste after its initial use. So it make me feel to make scale models through it. it is easily available and very cheap.
Step 1: List of Items Required
2.Cutter, scissor for cutting purpose
5.Thick drawing sheet.
6.Pen, Pencil, eraser, ruler, compass.
8.GI/ aluminum wire
12.LED Lights, wires, switches, battery
Step 2: Cutting of Card Board
First cut the available card board through cutter in such a way to get your model sides( right, left) I;e to get required height and width. Make sure that length is making proper ratio with width and both Left side and Right side are symmetrical in dimension only.
Step 3: Marking/ Sketching on Card Board
Draw sketch of sides roughly through pencil and then pen to get accurate lines over available left and right side card board.
Then cut with the help of cutter to get side windows, door, if any required.
Mark a separate line for wheel height level (skirt level) on both sides of card board.
Determine width of the model (bottom level, wheel height level, roof level) according to scale ratio, then cut card board for each level for keeping exact space between left side and right side. Along with cut some spacer to keep both sides stand vertical.
Step 4: Joining/ Cubing
Then join left and right sides card board with bottom level, wheel height level and roof level with the help of glue as specifically mentioned. Card board at roof level can be joined later with both sides.
Make sure to provide spacer between left and right sides card board to stand vertically for temporary purpose in order to avoid diagonal issue. Remove spacer when glue becomes dry.
Make sure to maintain sufficient time between step 4 and step 5 for drying of glue properly so that after removal of spacer, it shouldn't distorted from its original position.
Step 5: Cubing Stage-2
Similarly Draw outline/sketch on card boards for front and back side of model according to scale ratio and cut. Card board Portion of front and back side may b a single sheet or a combination of multiple depending upon design requirements, then Fit front side and back side with the model at a time or step by step as per practice/ constructive stage with the help of glue.
Similarly maintain time gap to ensure joints are properly fixed.
Step 6: Fixing of Trim Items
Place and fix model inside items like seats, bonnet, dashboard, sunvisor etc. and doors as per your choice and scale ratio by card board / drawing sheet.
Fix door handles, foot step, wiper, steering column, steering wheel with the help of GI/Aluminium wire with proper scale and ratio as per model.
Step 7: Fixing of Wheels/Tyres
With the help of compass, make circles on card board to have wheels, as regular available thickness of card board not more than 3 to 5mm, so make no of circles and cut with the help of cutter to have required thickness of wheel/tyre as per scale ratio.then join among circles with the help of glue. After getting tyre like thickness, engrave throughout circumference at particular interval to have tyre like shape and look.
Make hole at the centre of so called tyre formed by joining of circular card boards to insert PVC pipe as axle. Hole can be made at the earlier cutting stage of wheel.make sure that hole size shouldn't be large or small than PVC pipe size as it can be loose fit,
Then fix axle along with tyre by any clamping arrangements with the bottom level card board at wheel movement area.
As we are using scraps/ waste material for making this model, every used items considered here as easily available, alternative options can be adopted. Like in place of PVC pipe, different design/material/ thing can be used.
Step 8: Electrical Activity
Start doing electrical connectivity throughout model and keep provision that it can be fix before final fitment/ painting as per situation demands.
Fix empty capsules medicine cover for covering tail lamp, indicator, marker lamp etc.
Step 9: Fixing of OHP Sheet and Application of Putty
Fix OHP sheet as glass of door, windows and wind
Apply 2K putty over rough surfaces, outer corners, joints where ever required. Make sure that putty application thickness shouldn't more than card board thickness as it can crack after dry.(please don't use flame to fast dry putty)
After proper drying of putty, use emery paper to polish the same.
Step 10: Paint Application
Do proper masking to the OHP Seat area/glass area, capsules cover for avoiding over spray of paint on it.
Apply primer over putty and card board surface.then apply enamel paint as spray application. After drying of paint, remove masking.
Fix some sticker as brand name and for graphics also if required.
This is a static model, movement mechanism can be fixed after step-8.