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This project will walk through how to create a mini Stanley Cup trophy with foam coar that can be used to "Light the Lamp", if you don't have access to a 3D printer. On the left is the trophy we are going to build and on the right is the 3D printed version.

I have included images of the 3D print so you can see what we are replicating, but I will provide dimensions of the parts as we move forward.

Let's jump in!

Step 1: Project Materials

Materials

  • Foam core scraps (approx. 200mm x 100mm, a little extra for mistakes is a good idea)
  • Hot glue gun/Foam core glue (Elmer's)
  • Aluminum Foil (100mm x 100mm)
  • 1 - X-Acto knife or strong scissors
  • 1 - Compass
  • 1 - Pencil
  • 1 - Ruler

Optional

  • White duct tape or aluminum foil (to wrap the cup in when finished)

Step 2: Tip Before You Start

I am building my trophy to fit in the stand I 3D printed, which has a 32mm diameter opening where the trophy can be placed.

If you didn't 3D print your trophy stand, but crafted it from foam core instead, then your trophy stand opening may be different from my 3D print.

This build will start with the base of the trophy and the base is the largest diameter piece. It is important to make sure the size of the base will fit in your trophy stand before you continue to cut additional pieces.

Step 3: Create the Trophy Base

Using the compass and ruler, set the compass to 13mm or 14mm.

Remember: when setting the compass distance, you are defining the radius of the circle the compass will create.

A radius of 13mm or 14mm will create a circle with the diameter of 26mm or 28mm, which should provide a small gap between the stand and the trophy making it easy to place the trophy in the stand.

Use the compass to draw a circle.

Use an X-Acto knife to cut the circle off the foam core board, this will make it easier to cut the circle out with scissors.

Use scissors to cut out the shape.

Step 4: Create the Tall Section of the Trophy

The next section of the trophy is the tallest and will require 4 or 5 circle cut outs of the same size. I started by drawing 3 circles, cutting them out and seeing if they were as tall as I needed.

I ended up creating 5.

The diameter of this section should be slightly smaller than the base you created in the last step. I set my compass to 10mm, which created 20mm diameter circles.

Draw, trim, and cut out each of the circles.

Step 5: Rinse Repeat

Now that you have seen how to create circle cut outs and have already made a few, I shall set you free to finish up the remaining circles. You have already finished circles for the base and tall section.

In this step you will need to create the circles that make up the tiered section of the trophy.

To move forward you will need:

  • The base = 1 x 28mm
  • The tall section = 5 x 20mm

These were completed in the previous steps.

The tiered section:

  • Tier 1 = 18mm
  • Tier 2 = 15mm
  • Tier 3 = 12mm
  • Tier 4 = 10mm

Step 6: Glue the Bottom Pieces Together

You now have all the pieces you need, now you can start gluing them together. I lined them all up by size first, then worked my way down the line gluing and stacking the pieces.

Simply add some hot glue or Elmer's glue and stack each piece on the previous section. Make sure each circle is lined up with the circle below it before the glue dries, otherwise you will end up with a crooked Stanley Cup trophy.

At the end of this step, set your trophy aside to completely dry while you move on to making the trophy cup.

Great work, you are almost finished.

Step 7: Create the Trophy Cup

The trophy cup is made with a small circle cut out, with a doughnut shaped circle glued on top.

It is important to take some time to measure the sizes of these circles, because they need to connect.

Start by creating a 12mm diameter circle (set your compass to 6mm)

After drawing the 12mm circle, expand your compass a little larger than the 12mm circle. You can see in the images I just eyeballed this, but the diameter ended up being about 16mm.

This larger size circle will be the outside diameter of the cup.

Draw a second circle at 16mm in diameter.

Finally, return to the smaller circle and adjust your compass to a little smaller than the circle. Once you have the compass set, return to the larger circle and draw a small circle using the same center point as the larger circle. This will create the doughnut shape you need to cut.

Tip: For the smaller circles, I used an X-Acto knife and gently moved the knife up and down like a tiny saw to cut the circles, and then I trimmed with the excess material with scissors.

Once you have the shapes cut out, apply a small amount of glue to the doughnut shaped piece near the inside cutout.

Glue the doughnut shape to the smaller piece to create the cup.

Finish up by gluing the entire cup to the top of the trophy.

Step 8: Add Aluminum Foil to the Trophy

The last step is to add a small aluminum foil disc to the bottom of the trophy. This will connect the two terminals in the trophy stand when the trophy is placed on the stand.

When the terminals are connected the circuit is closed and you will "Light the Lamp"

Tear a small piece of aluminum foil (100mm x 100mm) and roll it up into a loose ball, then use a roll of duct tape to gently tap the ball flat to make a disc.

When the disc is complete, glue it to the bottom of the trophy.

Well done! You are ready to light the lamp!

Place the trophy into your stand to Light the Lamp.

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