I wanted to participate in a Trunk-or-Treat this year so I had to come up with a way to decorate my minivan. I came up with the idea of making a pirate ship minivan. I didn't want to hide the fact it was a minivan but rather embrace it and deck it out like a pirate ship. This Instructable is on making the mast and rigging, this turns your vehicle into a ship the rest of the decorating is up to you. Because this goes on a vehicle you may have to make modifications for it to work for you. The design is actually quite simple but requires a lot of different hardware (as I constructed the material list I couldn't believe how much stuff I used). There is a lot of leeway in the materials

Supplies

Tool List here is the bare minimum tools you need.

pencil

compass

tape measure

speed square

4' level (straight edge)

Drill

3/16" 1/4" 5/16" 3/8" drill bits

5/8" paddle bit

counter sink

circular saw

jig saw

grommet installation tool

hack saw

aviation snips

hammer

screw driver

two adjustable wrenches

scissors

file

lighter (to melt ends of rope)

iron

adding machine tape

Material List

Two pieces of 2x4 the length of the distance from outside to outside of your roof rack crossbars plus 2"

one 4' length of 2x4

3/4" plywood 1' x 2'

3/4" plywood 4" diameter disc (should fit loosely in 4" PVC pipe)

1/4" plywood just bigger than the diameter of your bucket (see below)

5' length of 4" PVC pipe

3' length of 1 1/2" PVC pipe

5' length of 1 1/2" PVC pipe

6' length of 3/4" PVC pipe

2' length of 3/4" PVC pipe

ten 1 5/8' #8 bugle head construction screws

two 1 1/4" #8 bugle head construction screws

1/4" carriage bolt 5" long

1/4" eye bolt 3" long

1/4" eyebolt 3 1/2" long

three 1/4" washer

1/4" fender washer

three 1/4" nylon lock nuts

1/4" wing nut

3/8" hex bolt 6" long

3/8" eye bolt 8" long

two 3/8" washers

3/8" fender washer

two 3/8" nylon lock nuts

two 5/16" hex bolts 8" long

four 5/16" washers

two 5/16" nuts

two 5/16" wing nuts

one 3 1/2" carabiner

3" L shaped corner brace

twenty 1/2" grommets

spray glue

duct tape

1/4" poly rope

4' wide by 6' long canvas drop cloth (sail)

six 30" bungee cords

two 24" bungee cords

three 18" bungee cords

10" +/- high by 10" +/- diameter bucket (this can be a pail, bucket, plastic flower pot, pumpkin candy basket)

12" x 18" pirates flag

Step 1: Building the Base

This will require the two 2x4s, 3/4" plywood 1' x 2', the plywood 4" diameter disk, 1 5/8" screws, and 1 1/4" screws. The mast much attach to the roof rack of your vehicle, so this is the best place to start. First, measure the distance from the outside to outside of the crossbars (these are the bars that go across the body of the car not the ones that go along the sides) on your roof rack, and write this number down. Note; these usually slide, so make sure the measurement is the same on both sides. Second, measure the distance in between the crossbars. Third, measure the thickness and width of the cross bars. Take the first measurement and add two inches, this is the total length of the 2x4s. Take your 2x4s, and starting at one end (this will be the back) measure the width of your cross bar and make a mark. From that mark, measure your second length and make another mark. This should leave the width of one crossbar and two inches (this end will be the front). Then, square up your mark from one inch from the top to the bottom. Draw a parallel line one inch from the top to your vertical line, the lower corner gets cut out leaving a one inch tab to sit on the crossbar. At the other end, measure two inches back along the bottom edge of the 2x4 and place a mark and square it up about an inch and a half. There should be another at this end. Square it up in the middle of the 2x4 (not touching the bottom or the top). Measure down one inch from the top and make a parallel line from the middle line to the end. Measure down from the one inch line the thickness of the crossbar, and make another parallel line from mark to mark. The top line is cut from the end and the bottom is cut two inches short of the top. Then, the center portion is removed. The end result is a piece of 2x4 that will rest atop both crossbars. When slid forward, the front goes around the crossbar, while the back drops down, not allowing the front to slide back. Cut both 2x4s the same way.

Next, we will drill the 1' by 2' piece of 3/4" plywood from one of the ends. Measure in 2 5/8" from one of the ends, and measure 6" from the side. Drill a 1/4" hole. From the same end, measure in 6" inches from both the end and the side and drill a 3/8" hole. Layout holes for the 1 5/8" screws four on either side 3/4" from edge, 1 1/2" from the ends, and 7" apart drill with a 3/16 bit and counter sink. Screw plywood to edge 2x4s holding the plywood back even with the back of the notch. I've included pictures of making the 4" disc. I used a thin piece of 4" PVC and traced it. Drill a 3/8" hole in the center of the 3/4" by 4" plywood disk, and screw it down so it lines up with the 3/8" hole drilled in the deck. I used the 3/8" eyebolt to line up the two hole prier to screwing it down. Lastly, put the 5" long 1/4" carriage bolt through the deck sticking up, and secure it with the 1/4" fender washer and 1/4" nylon lock nut.

Step 2: Building the Mast

For this step, we will be using the 5' length of 4" PVC, the 3' length of 1 1/2" PVC, two 5/16" hex head 8" bolts, two 5/16 nuts, four 5/16 washers, two 5/16 wing nuts, 3/8" hex head 5 1/2" bolt, 3/8" by 8" eye bolt, two 3/8" washers, 3/8" fender washer, two 3/8" nylon lock nuts, and the carabiner. Start by drawing a straight line down the length of the 5' length of 4" PVC pipe. Now draw a line down the other side half way around the tube. Any easy way to find the opposite side of a pipe is with a strip of adding machine tape. Take a length of the tape wrap it around the pipe and mark where the two over lap, this is the circumference of the pipe. Next fold the paper in half, this is the exactly half of the circumference. Place the paper on the line you made and mark the back of the pipe. It is important these lines are opposite each other so the drill holes line up. The 8" eye bolt should measure 7 3/4" from the end to the far inside edge of the eye. Subtract 1 11/16" from 7 5/8" and you get 6 1/16"". Measure up from one end 6 1/16" on the lines you put both sides and drill two 3/8" holes (the hole should line up with one another), this will be the bottom. Now from the top down measure 1" and 5" on the lines on each side and drill four 5/16" holes. Now take the 3' length of 1 1/2" PVC pipe measure up 1" and 5" and drill two holes straight through the pipe (I actually drilled these holes from each side as its easier to make sure the holes are in the correct spots). Now we can connect the mast to the base. Put a washer onto the 3/8" hex head 6" bolt and slide it into one of the 3/8" holes. Insert the 8" eye bolt into the end of the 4" PVC pipe and push the 3/8" bolt through the eye and out the other side of the pipe. Secure the bolt, a 3/8" washer, and nylon lock nut and tighten. Put the end of the 3/8" eyebolt through the four inch disc, and out the bottom of the base. The pipe should seat nicely around the disc. Secure with a 3/8" fender washer and nylon lock nut and tighten, the head of the bolt should be facing the front. Place a 5/16" washer on each of the 8" bolts. When you slide the first bolt through the first hole in the 3' length of 1 1/2" PVC pipe, insert the carabiner into the end and pass the bolt through it as well. Slide the other bolt through the other hole and secure them both with 5/16" nuts, tighten. Now with the carabiner hanging down, slide both bolts through the front top of the mast and tighten it on with two 5/16" washers and wing nuts.

Step 3: The Sail

The sail consists of the upper yardarm made from a 5' length of 1 1/2" PVC. A lower yardarm made of a 6' length of 3/4" PVC. The fabric sail which is made from a 4' wide painters drop cloth cut to 68" long. Also used in this step are the grommets, a 1/4" by 3 1/2" long eye bolt, 1/4" washer and nylon lock nut, rope, duct tape, and spray glue. Drill a 1/4" hole through the center of both yard arms. Install the 1/4" by 3 1/2" eye bolt in the 5' long 1 1/2" pipe, secure it with a 1/4" washer and nylon lock nut. This will be the upper yardarm. Put a double layer of duct tape over the ends of the pipes and trim with a pair of scissors. The sail is made by taking the 68" length of 4' wide drop cloth and measuring in 6" in on the top edge of either side. Draw a line from the bottom corners to the marks on both sides. Spray glue from the line to the outside edge fold the corner over and glue it down. The finished size of the sail is 48" tall, 68" wide on the bottom, and 56" wide at the top. Install ten grommets along the top and bottom. center grommets 3/4" from the bottom and top edge. Place the center of the first grommets 2" from ends. place a pair of grommets 1" to the left and the right of the center of sail. The remaining grommets are spaced every 6 1/4" along the top and 7 3/4" along the bottom. The sail is attached to the yardarms with short lengths of rope 12" long for the bottom and 14" long for the top, make ten of each. Melt the ends with a lighter and tie in a knot. Put the string through the grommets and tie around yardarms. Wire ties could be used, but don't have the same look. Attach the sail to the mast by hooking the eyebolt in the upper yardarm to the carabiner. Take the lower yardarm and slide it onto the 1/4" bolt sticking out of the base and secure with a 1/4" washer and wing nut.

Step 4: The Crow's Nest

This is where the bucket comes into play. This can be almost anything; a pumpkin candy basket, a plastic flower pot, a sand bucket, etc. I used a plastic Halloween planter with a jack-o-lantern face painted on it. First, cut a hole in the center of the bottom 1 7/8" in diameter. I fine tuned the hole with a file or rotary tool if you have one. To keep it from flopping around, I cut a piece of plywood to fit the crow's nest about 1 1/2" down from the top, this is what the 1/4" piece of plywood is for. If you are using a bucket, the diameter constantly gets smaller the lower you get. Measure down 1 1/2" and measure the diameter at that point. Using a compass, lay out a circle the same size on the plywood. Cut a 1 7/8" hole in the top for the mast to go through. I allowed gravity to hold the plywood in place. The crow's nest just slides down over the upper mast and sits on top of the main mast. The pirates flag is next. Take the 2' piece of 3/4" PVC and drill a 1/4" hole through it 1/2" down from the top. Secure the 1/4" by 3"eye bolt with a 1/4 nylon lock nut inside the pipe not on the outside. Open the eyebolt and attach the top of the flag and close it. I used my two adjustable wrenches to easily bend the eye bolt, you don't want to put too much pressure on the PVC. Slide the pipe into the upper mast. It should rest on the the eye bolt. Loosely tie the bottom of the flag around the mast. This allows for the flag to be easily removed so the crow's nest can come off and on.

Step 5: The Bowsprit

This is the last piece that needs to be made and uses the 4' length of 2x4. First, it needs to be shaped. Make the first 10" 1 1/2" wide (this will be the top). Then, just sketch a rounded transition from the 1 1/2 width to the full 3 1/2" 2x4 width. I cut the other end at a fifteen degree angle long point on the bottom. Two holes need to be drilled through the 2x4. Measure 8" and 30" from the back end. Measure 1 3/4 down at each mark and drill two 5/8" hole through the 2x4. Take the 3" L shaped corner brace and cut one side down to 1/2". The corner brace measures 2 7/8" on the inside, so measure up from the bottom corner of the 2x4 2 5/8" and place a mark. This will be the top of the corner brace. Screw the corner brace in the center of back end of the 2x4. It should hang down a 1/4" off the bottom of the 2x4. This bracket hooks the top of the car hood. Take note, this could potentially scratch your car. If you are worried about it, protection of some sort would have to be applied.

Step 6: Putting It All Together

It is finally time to attach the mast to the car. This is where the rope, bungee cords, and Styrofoam skull come in. First take the base with mast, crow's nest, and flag (no sail yet). Hang six 30" bungee cords from the top of the 4" PVC mast (three on each side). Place the whole mast assembled on your roof rack, slide it so the notches engage, and lock it on. Slide the assembly to the center of your vehicle. All of the rest with the ropes will be custom to your vehicle. Take the first bungee cord. Pull it tight straight to the side of the mast and measure the distance from the hook to the rail of your roof rack. You will need a loop of rope to make this distance up. The loops make for very fast assembly, and eliminate the need for all sizes of bungee cords. Wrap the loop around, and put the one end through the other and you are done. The loop needs to be the measured length, plus the circumference of the roof rack rail times two, with a little extra for a knot. Make two, one for each side. Next, measure the second one the same way. This one goes to the center of the rack (in my case there is a middle support pillar that it goes behind). Again, make two. The last set goes from the mast to the rack rail behind the cross bar. With the six of these in place, the mast looks like its been properly rigged. Hang the upper yardarm from the carabiner with the sail attached. Place the lower yardarm over the 1/4" carriage bolt and secure with a 1/4" washer and wing nut. Next, we must attach the bowsprit. It hooks on the top center of the hood. I used two 18" bungee cords and a short loop of rope to go from the rear 5/8" hole in the bowsprit to hook the front edge of the hood. With bungee cords pulling forward, the rear hook stays engaged on the hood. The Large Styrofoam skull is placed under the bowsprit. I used a skull, but you could use anything you like. I used two 24" bungee cords and another loop of rope to go from the front hole in the bowsprit in front of skull, and down to the underside of the bumper. This second set holds the skull on, and in place. There are two more ropes to attach, and then we are finished. A rope goes from the mast to the bowsprit, and from the mast to the back of the tailgate. Tie the front rope right under the crow's nest, and to the front hole in the bowsprit. Tie the rear rope from the top of the 4" PVC pipe to the tailgate (I hooked the tailgate with a 18" bungee cord and tied it to that). After this first time, I like to attach the front and back ropes before I install the mast because its much easier. Now that the build is complete, it can be painted if you like. Much of my PVC was white, and had to be painted. Now, you are ready to set sail, figuratively speaking. I wouldn't drive on the road with it.

Step 7: Decorate the Finished Ship

I've added the photos of my minivan pirate ship fully decorated. After the mast is on, you can accessorize and decorate it however you like. In these photos I'm using an 18 volt power inverter to power four purple light sets, the green LED projection light, and the water LED blue/green projection light.