Step 1: Materials and Tools.
- Corrugated card - enough to draw three copies of the template - maybe one and a half sheets of A4?
- plain paper for templates.
- Glue - I used PVA craft glue, but anything that sticks card will do the job.
- String - three or four metres of slightly-rough string. Not the hairy stuff, but slightly rough.
- A drinking straw.
- A cocktail stick or bamboo barbecue skewer.
- Cutting tools - scissors, craft knife etc. If your card is thick, you will need a large sharp knife like a Stanley knife (I believe Americans call them box-cutters?)
- A drill - it is far easier to drill through several layers of corrugated card than it is to poke a hole.
- A piercing tool - something to make a small hole in the card, such as a sharp pencil, a nail etc.
- Printer or drawing tools.
Step 2: The Gorilla Template
I hand-drew the original (see the scans), and you can do the same, or you can print off a copy of the scanned-and-drawn-over version I have attached as as a PDF. If you cannot see the full-size scans, don't worry. They are mainly an archive of the design process - the PDF file contains everything you need.
Notice that you need several layers of card - the torso and arms are made of three layers, the legs are one layer and the head is an added piece.
- I tilted the different layers of the torso at different angles compared to the ridges in the corrugated card. This made the finished model stronger than if all three layers were at the same angle.
Step 3: Construction (1)
Step 4: Gluing.
Don't be mean with the glue - like a composite material, the glue provides a lot of the strength of the finished toy.
Depending on the type of glue you use, lay the torso pieces under a book for a suitable time (overnight for the PVA).
Step 5: Construction (2)
Glue the head onto the front of the torso, in an aesthetically-pleasing position.
- You will need to add features to the head - you can draw them directly onto the card, or onto the plain paper and then glue that onto the front of the head.
Step 6: Something to Climb.
With the remains of your corrugated card, make a simple beam, about as long as the distance between the gorilla's hands.
Drill two holes near the centre of the beam, and and a hole near each end.
Tie a loop of string through the centre two holes to hang the gorilla up.
Cut another piece of string about four metres long, and thread each end down though the holes in the ends of the beam. You could use two separate pieces, but using one piece removes the chance of knots pulling through holes. To stop the string slipping, I glued and wedged short pieces of bamboo skewer into the holes with the string.
Thread one end of the string through each hand of the gorilla, and then tie a large knot in the end of the string to stop it pulling back through the straw. You could, if you want, add a large bead.
- I made "beads" by cutting short lengths of the corrugated card, gluing along their length and then rolling them around the knotted ends of the string.
Step 7: Climb!
Pull each string in turn (left, right, left, right), and the gorilla will climb the string, legs swinging.
(Adding the video was gmjhowe's idea)
Step 8: Improvements?
You could do these, of course, but after spending three days looking at his ugly mug, Gorilla kind of grew on me.
I like him the way he is, and I'm not going to change him.
If you, however, make him differently, or make a different animal climb the string, then please post pictures of your creations in the comments. I'd love to see them.
PS for non-pro members, I have added the PDF to this step.