1/8" Baltic Birch Plywood
Solar Yard Light
Tape (may need) (might also need scissors)
Nuts, Bolts, Lock Washers & Washers
Screwdriver and wrench
Small Plastic Tube
I found the solar yard light at the Dollar Tree (for yes just $1) I have also seen similar ones at Menards for $3-5)
Step 1: Design Robot
I used Boxit 4 times for the head, body, one leg and one arm. Then copied the one leg and one arm so I now have two legs and two arms.
I measured the solar light and that determined Robbie's minimum head size. I added an extra inch width to his head because I thought it looked better.
The eyes are lower to account for the solar light height.
The center eye hole circles are sized to hold LEDs (and LED holders) if I wanted to wire them in later.
The body was just to look good with the head, has the same depth as the head.
I designed the gears and named him "Robbie" the kiddy name for Robot.
The arms were designed to look proportional to the body & head.
Depth is half the body depth.
The legs are the same depth as the body.
Wanted short legs for better stabilizability.
I have added the file so you can cut the design out on a scrollsaw or have a laser cutter cut the design. It is just the outline of the robot, so you can add your own face, heart (or gears) and name. I also have the robot laser cut wood listed on Etsy & Zibbet in my AmysCrazyCrafts store.
Step 2: Cutout Design
Sand with 220 grit sand paper, electric sander will result in a smoother finish then hand sanding.
Step 3: Layout Pieces
Then glue only 5 of the six sides. (Do not glue opposite side of holes for the arms and legs, back of the main body and top of the head.) This will allow access to install the nuts and bolts and the solar light.
Wipe extra glue with a Q-tip.
Step 4: Bolt Robot Together
How this setup lays out:
Head of bolt inside arm or leg, Washer, wood, washer, wood, washer, lock washer, nut.
The head has a small plastic tube instead of a washer between the pieces of wood.
Tighten bolt and nut snug.
Step 5: Installing Solar Light
Line up solar cell with square hole in top of head.
Glue top of solar light to top of head.
Note: may need good quality tape to keep in place.
This solar light will charge under lamp light.