Build a 6'-0" tall Wooden T-Rex Model

I'm sure we've all seen those small wooden 3D dinosaur models. I had a few that I loved as a kid, but they all shared a common flaw. They were much too small!! As a father I set about to rectify that problem for my son. In the following steps I'll provide all the information you'll need to make your very own 6 foot tall T-Rex model!


(Please vote for me in the DADCANDO contest!!)

Step 1: Tools & Materials

MATERIALS:

2) 4'x8' sheets of Oak Plywood (*see notes below)
Templates printed on 24"x36" sheets (from attached PDF on Step 2)
Wood Stain & Finish (optional but recommended)
Felt with adhesive backing

TOOLS:

Jigsaw
Jigsaw blades - 12tpi (teeth per inch) skinny blades
Drill with 1/4" bit
Sander w/ various grits
Router w/ 1/4" roundover bit

*NOTE: My T-Rex was sized and built using 1/2" thick plywood. Upon completion I realized that the legs, tail, and spine are a bit too flimsy. I'm going to recut just these pieces using 3/4" plywood. I would recommend using 3/4" thick for this project if you only want to buy two sheets of plywood, but keep in mind there is a weight advantage by using 1/2" for all the other pieces. I went with oak because it has a nicer grain and accepts stain better than pine. If you choose to go with pine, you'll need to use wood conditioner before applying any stain.

Comments

[fossilbabe]

Just love this guy and thank you so much for doing this for us. It was so easy a cave woman could do it. Looking to make more and so excited. I would love more patterns if they come avaiable. Fossilbabe

[kaptaink_cg]

Awesome! Glad you enjoyed it!

[DieOog]

Thanks for this instructable. I built a T-Rex using my XY table for my son's ninth birthday party. I buried all the bits and had the kids dig it up as archaeologists and assemble it. The kids had so much fun they did not want to go home again.

Once again thank you for your effort.

[kaptaink_cg]

That sounds awesome! Can you post any pics from it?

[woodenparrot]

Quite dangerous to flip your router upside down ? You bet. I cut away a big hunk of a finger doing that about 17 years ago. The router grabbed the piece I was holding and sucked my hand right in. Ouch!

[Robert McGrath]

wonderful, thanks for making the plans available.

I adapted the Pterodon plans to cut with an Epilog Min laser at the Champaign Urbana Community Fab Lab.

Here is a blog article:

http://cucfablab.org/blog/pterodon-project-adapted-instructablescom-inlcudes-plans

[Michell Kwon]

waw.. u made a big Tyranno! I bought 2.25cm Miss Tyrannosaurus almost 5 years ago, and now she has severe arthritis..! wooo.. but I love her!

[kaptaink_cg]

That's awesome!!

[somethingsaurus]

This is what I built with help from the local CNC.

https://lh6.googleusercontent.com/-TXCqsDGaS0Y/TqIsMP82IJI/AAAAAAAAJqw/dLMsojsG4XQ/s720/P1050086.JPG

[tinker234]

add to my shop

[Mischievous1]

I don't understand the cloud. Is there or is there not a cloud ? Why ? And if there is, how do pieces 8 and 3 hold together ?

[kaptaink_cg]

Yes, there is a cloud marked on piece 8 to remind you to check the slots against piece 9. The question is answered in greater detail in one of my comments below. In the main photo on step 5 you can see my son putting these pieces together. Piece 3 slides into piece 9 and then piece 8 attaches.

[Mischievous1]

Okay ! Thank you for your answer ! This cloud has been very confusing for me, I had not understood what it meant : I thought it was part of piece 8, I drew it and cut it in the wood (!!!) (And it did not fit very well with pieces 3, as you may imagine) Well, it learns me I should read all the comments before trying an instructable. I love this one. I will post photos of my little T-Rex soon. Thank you ! (PS : I printed the pdf on A4 paper, and my T-Rex happens to be only about 60cm high (sorry, I'm french, I don't measure with inches or feet. It must be about 2 feet high, a little less). How was I supposed to print it, so that it would be 6 feet tall ? I don't think I can put anything else than A4 paper in my printer...)

[kaptaink_cg]

Sorry for the confusion. I've had a couple questions on that.. Maybe I should have dashed the cloud in or put a note on the piece. I would love to see pics once you have it complete! For the 6' tall model you have to print on 24"x36" paper. (Arch D) In metric that would be an ANSI D sheet, but it'll be a little undersized. ANSI D converts to 22"x34" in imperial. You'll have to take the file to a printing service or maybe find a drafting company who can print it for you.

[Mischievous1]

Thank you for your answer ! Here is the photo. It is 55 cm high, made with 10mm plywood. (One piece is missing in the tail, I had lost it when I took the photo, just found it back.) It's not perfect and it's got a few problems (particularly around piece 8, that I will have to do again), but I learned to use the jigsaw with this instructable, so I'm still happy with what I've done. About piece 8 : I've cut the cloud, but did only 2 notches, and I don't undestand why there should be a third one : one notch for each piece 3 (right and left), and what is the third one for ? I haven't got a router, and I was wondering what it was for. Making round edges on the pieces ? Is it really important, does it change the T-rex a lot ? I couldn't see on the photos. Is it a usefool tool? Isn't it a little expensive ? Are you planning on giving the plans of another dinosaur ? I'd love to try a new one !

[kaptaink_cg]

Looks Great!! OK, to answer your questions: -The third (middle) notch on 8 allows the spine and tail sections to meet up. Not overly critical, but looks a little nicer that way. -Yes, routers typically are used to round edges, but can also create nice, complexed edges, and can also cut grooves in wood. -Overpriced? Depends on which one you buy and how often you use it. I wouldn't buy one just for this project. (in fact, I borrowed my dads...again.. lol) -No, it doesn't change it a lot, it just makes it look a little more "finished" You could achieve the same effect by sanding down all of the edges, but that would take forever. -Other dinosaurs.. yeah I'm considering it. Was thinking of making a smaller scale pterosaur. (i.e. more affordable) but I haven't decided yet.

[akgooseman]

My spine and tail weren't very stable, even held by piece 8. I screwed metal splice plates alongside the notches in the spine and tail, above the slots, so they wouldn't interfere with the other pelvic pieces. It's rock solid now. Paint/stain blends the metal in with the wood. Awesome instructable and a great birthday present for my paleontologist girlfriend. I used 5mm ply for the bird and 3/4" ply for the strong-jawed walker. We'll tuck these bad boys on the edge of the woods bordering the road so sharp-eyed passers-by can enjoy them. Thanks!

[Mischievous1]

Ok ! Thank you very much for your answers. It's the first instructable I achieve, and I'm really happy with the result. Be sure I'll vote for you at the "dadcando contest" as soon as I will have understood how to.

[action pig]

I searched "laser puzzle dxf" into google and came up with a bunch of sites promising free downloads. The bee puzzle looks particularly interesting...

[SirMonkeyBalls]

Hey, great instructable! It took me a couple weekends to finish mine. I had a blast completing it, and made a little video of the final assembly...Enjoy! http://www.youtube.com/watch?v=7QYGfGb8-_8

[earlye]

So funny to see this show up as part of the instructables email today. I just finished cutting and assembling, yesterday, a pteranodon as the first in my 3-member dino-menagerie for Halloween. I plan to suspend him from the house such that he looks like he's flying out of the garage. (Don't know if this link'll work or not... If not, there's a few progress photos...) http://www.facebook.com/album.php?aid=2059274&id=1522353866&saved#!/album.php?aid=2068825&id=1522353866

[kaptaink_cg]

Check out the Bonus Step I just added to the end of the instructable.

[kaptaink_cg]

Cool, that was my next project as well actually! What are the other 2 members of your menagerie going to be? I'd love to see a Stegasaurus. BTW, your link didnt work. Maybe try posting some pics directly in your reply?

[somethingsaurus]

I have access to a CNC machine and i think that I am going try your method with a few tweaks. What about arranging the pieces on the scanner to fit in the 4x8 space? Do you know the copyright of the original models?

[kaptaink_cg]

I believe most of these models are public domain. I've found this particular layout EVERYWHERE. I recently bought a micro model, he's only about 1" long when complete, and it's the -exact- same model. The only one I have seen that's different is a recent model from Michael's craft store.

[earlye]

For mine, I scanned a balsa pattern, rearranged the pieces in Inkscape (great open-source vector graphics app) until they fit very snugly into a 4x8 rectangle. I then hooked laptop to projector, and scaled the entire drawing until it consumed the entire sheet of plywood. Trace, paint, cut, done.

[somethingsaurus]

If you have the file, it would save me a lot of time. I have another dinosaur coming that I am going to scan too. I would be happy to share that file with you regardless.

[kaptaink_cg]

Check out the Bonus Step I just added to the end of the instructable.

[earlye]

I have to look at the box for copyright info; if it looks kosher I'll post. The inkscape approach didn't take very long - the main thing was to avoid resizing the bits once they were traced. It'd be nice if you could put it in a mode where the sizing widgets are disabled. Maybe an hour or two for that.

[confortif]

I'm thinking about building this in 1/4" steel to put out in the yard. I can cut the metal with my plasma cutter by following a line but it is best if I use a wooden pattern which requires me to offset the pattern lines for the plasma nozzle size and that takes me modifying the CAD model before plotting it out. It is obvious you created the pattern using a CAD program of some sort. I was wondering if you would share the CAD file?

[kaptaink_cg]

Check out the Bonus Step I just added to the end of the instructable.

[fizzix18]

Great work, nice project. It would be nice if you would share your CAD files (DXF, SVG , CDR or whatever) with the rest of us, I would like to cut out the part with a laser cutter at a FabLab.

[kaptaink_cg]

Check out the Bonus Step I just added to the end of the instructable.

[somethingsaurus]

Found a German site that might have what you need. Here is the t-Rex http://www.blechwelt.com/teil_des_monats/dxf/Tyrannosaurus-1.dxf Here is the main site: http://www.blechwelt.com/teil_des_monats/archiv Lots of CNC/laser cut stuff there and he got the t-rex on one sheet! And there is this: http://www.epiloglaser.com/sc_dino.htm

[kaptaink_cg]

EXCELLENT Website. Tons of projects in there! (thank you google translator)

[somethingsaurus]

Now I just need a few other dinos and I got it going on. Freeside Atlanta (www.freesideatlanta.org) has a visiting CNC expert. He got our sputtering machine running and is teaching me how to build a better one. (future instructable.)

[kaptaink_cg]

I'm considering it... Maybe if I place in the contest... (hint, hint).. LOL

[somethingsaurus]

If you do have a CAD or vextor file, that would be great. I have a triceratops model coming today and when I build them both to people size, they will fight.

[kaptaink_cg]

Check out the Bonus Step I just added to the end of the instructable. Can you upload a scan or something of your Triceratops model? I'd like to make some pieces for that if you havent already.

[somethingsaurus]

I tried to scan it but it did not come out right. The site I linked to has the same model (http://www.blechwelt.com/teil_des_monats/dxf/0405-Brontosaurus-3mm.DXF) Not really a brontosaurus...