This large-scale Grinch Operation Box is reminiscent of a childhood favorite game. The goal is to remove the Grinch's bones without touching other parts of the box. If touched, the Grinch's red pupils light up and he makes sound!

Supplies

•1/8” Birch Plywood

•1/4” Birch Plywood

•Trotec Laser Cutter

•Prusa Mini 3d printer

•PLA

•Glue Stick

•Thingiverse.com

•Audacity

•Electric sander

•Titabond Wood Glue

•Nails

•Hammer

•Clamps

•Red Leds x2

MPR 121 Capacitive Touch Sensor

Step 1: Plan Construction and Design

Before starting my project I did research on the operation game and how it works. I put together a plan for my build, and figured out how large scale I wanted it to be. Then I made a powerpoint of inspiration photos to figure out the design.

Step 2: 3D Print Bones

The first element I constructed was the operation bones. I looked for inspiration in thingiverse and then created my own gcode file. I used a prusa mini 3d printer and pla to print the pieces out. To make sure my prints were clean, I added a brim and used applied a coat of glue stick glue to the bottom of the base.

caroline2_0.15mm_PLA_MINI_2h55m.gcode
Download

Step 3: Laser Cut Box

The first piece I started with was the top of the box. In order to cut the top of the box to be in scale with the bones, I took a picture of the bones on a dark background. Then using adobe I was able to edit the outlines.

To make sure that the bones fit, I made several practice cuts on cardboard. It is important to make sure that the cuts you make are a bit bigger than the bones for the pieces to fit. I then chose my design and placed the cuts appropriately. Engraving is optional but serves as a nice outline for creating the Grinch art.

Next, laser cut the sides of the box.

Attached is my adobe files for both the top of the box and the sides.

Step 4: Assemble Box

Following, assemble the box. I used corner clamps and titebond glue. Once dried, I secured the box with table clamps and put nails in the corners for extra security.

Step 5: Sand Down Rough Edges

In order to clean up the edges, I used an electric sander. This made my box even and ready to paint.

Step 6: Fit Tin Pans to Cut-outs

I used aluminum tin foil pans as the bins for each bone piece. I cut the height of the tins in half, and then carefully shaped them around each shape for an optimal fit for each 3d printed bone piece. Following, I connected them all with copper wire tape.

Step 7: Paint

Paint the bones the color of your liking. I painted The Grinch in traditional colors using acrylic paint.

Step 8: Additional Touches

For additional touches, I added glitter and sealed it with a coat of matte mod podge. I also created a felt Santa hat with a pom pom to sit on The Grinch's head. Additionally, red holiday tinsel outlines the box.

Step 9: Set Up the Led Eyes

Drill holes to create the space for the leds. Once made, carefully place the individual lights inside the holes.

Step 10: Connect Electronics

I connected my electronics to the back of the board so that they would be hidden from the user. I used an Arduino Nano RP2040, a breadboard, breadboard pins, alligator clips, a speaker, a battery pack, and an MPR121 capacitive touch sensor.

The pictures included show my set up!