I tried this project with my grade 8 Puzzles and Boxes class and they were a hit. The kids wanted to play as soon as one was done and ended up having a round robin for 1/2 a class. I'm flexible ... :-) At one point the vice-principal came in. The kids pulled him onto a game. I believe he won because as he left the shops he was pumping his arm in the air. Victorious. This game is great for everyone because it is really challenging but easy to learn. My daughter has beaten me 5 times. She is 9. Oh man i will NEVER live that down.
Try it out. The project is of both wood and metal but each part really is not too tough. You can out the welding part if you don't have the facilities. You can do the whole project with hand tools if you like. In this instructable I'll present what i do as a shop teacher and offer tips and suggestions as well as a marking sheet for teachers but really, anyone with a basic set of tools can build it.
Have Fun!
THE LESSON PLAN...
In this instructable I will Show the steps needed to build the project divided into the WOOD part, the DESIGN part and the METAL part.
-The students will learn to shape wood than apply the skills in the construction of a wooden checkered board.
Shaping tools will depend on what the teacher decides is appropriate...
-Hand tools involve the Backsaw and Handplane
-Power tools involve the bandsaw and drill press.
-Gluing methods will also be demonstrated than applied to create the board.
-The students will learn design methods including mindmapping, discussion, problem solving and sketching than use these design methods to solve a metal design challenge.
-Once the students have arrived at a design solution they will be required to learn and demonstrate the use of metal-working tools including the hacksaw, file, bending jigs, vice and MIG welder. (if the teacher requires it)
MATERIALS:
-About 6" by 10" by 1/2-1" thick wood. Two pieces, contrasting colors.
-3/16" steel rod... about 1-2' .
-EMT steel tube. you need about 6" each of 1/2" and 3/4"
-Steel pipe 1/16" wall 3/8" OD
-Very small 1/4" pipe, rod or wood dowel.
*** a note on the tubing . If you go to an electrical supply place they'll give you more than you need of pieces they use to practice bending with. The sizes are not critical... you just need 4 sizes that will sleeve together.
TOOLS:
-Backsaw, Hand Plane
-Bandsaw, Drill press
-MIG or Oxyacetylene
-Hacksaw, files, bending jigs, vice
-Sandpaper 80, 120, 180, 220 Grit
***a note on the tools. I use both hand and power tools and both styles can be used separately or together. Steel joining tools such as the MIG or 'torch are not required... I give an example the project with and without them.
Submitted by HD Stafford Middle School for the Instructables Sponsorship Program
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Signing UpStep 1Making the Board Strips
I start with the Board base because the metal part builds on it.
You will first need to break out the strips of contrasting wood. The pieces should be 1" wide by about 12" long. The thickness depends on what you have but 1/2" is a reasonable minimum.
I will teach the kids handwork depending on the ages and skills... Prep work with the table saw will make the job faster and easier with great quality but it is good to do the basics too so it is up to you. I give suggestions below...
By Hand...
Use the backsaw to cut the pieces to rough length. Use the handplane to start with a face side. A square and ruler can be used to mark the other parallel side. I know this isn't to the usual build practices but I've found that kids can more easily see what they are removing if the sides are parallel rather than marking and planing the perpendicular (face edge) side. Make sure the pieces are the same size and are at least 7/8" wide. After the sides are done the kids can rough plane the face and bottom after glue-up.
I would suggest sharpening the planes and setting them up prior to class. Make sure the blades are hardly protruding at all. I find the kids get really frustrated with planing if the tool jams at all.
The Hand method (with some help)
Another option is if you break out all the stock in long lengths to the correct width with the table saw first... leave the hand planing for face and bottoms. I never let kids use the tablesaw, jointer or planer. They are only in grades 6,7 and 8.
I use 2 methods for glue up... have 9 strips of contrasting alternating wood than rip it down the middle of the center piece with a bandsaw or just glue up 4 pieces... 2 light, 2 dark pieces. The first method is good if you want to make a number of boards and are using a tablesaw to do everything in volume. I will usually do 3 or 4 extra for kids who are trying their best but are just not having success... this allows them to do the design and metal sections without being too discouraged.
The BIG GLUE
Teach the kids to apply wood glue to both edges of the wood strips. I would suggest they mark tops and bottoms now before gluing... they can choose the best faces to have showing.
Put the pieces in the vice or jorgensen clamp and tighten the pieces together. Spend time running around to make sure the pieces are not creeping up and down, mis-aligning the faces. A trick I use is to let the pieces sit for 3-5 minutes all perfectly set up with glue before clamping. This sets the glue a bit and slows down the creeping tendencies...
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I had that same problem with Gobblet selling out early the 2010 Christmas season. Lee Valley seems to only restock it during the holiday season, I made sure to run to the store when I noticed they had it in stock again, think it was November'ish 2011. So, if you're still hoping to buy it, you should be able to in about 7 months.