Pony Pals

Sometimes a project comes from the combination of two inputs. One was amalkhan's Instructable on making a cardboard toy horse. The another was my Granddaughter's passion for My Little Ponies.

This Instructable allows you to make four different types of Pony Pals. Just follow the instructions.

Step 1: Acquire Cardboard and Cut Pieces

To build you pony you will need 30 pieces of cardboard, at least 24" x 30. This works out to five sheets of 48" x 96" cardboard pads or 30, 24" x 30" cardboard pads. If you want to scrounge the cardboard I recommend you go to a new housing tract and get the boxes the cabinets came it, after the installers discard them. Another source is large screen TV boxes.

There are five different patterns that are need to build a pony. They are shown in attached PDF. The five patterns are also included.

The type of pony you make dictates the quantity of pieces for each pattern type you will use and the order they are stacked. The following need:

Pony 12A, 6B, 12C, 6B, 12A

Winged Pony 12A, 5B, 1B' 12C, 1B, 5B, 12A

Unicorn 12A, 6B, 2C, 8D, 2C, 6B, 12A

Winged Unicorn 12A, 5B, 1B', 2C, 8D, 2C. 1B', 5B, 12A

Each pony has 48 pieces that will be lamenated together.

Determine the pony you want to build, collect the cardboard, and cut the pieces using a laser. Again the DXF files are included.

Step 2: Glue a Pieces

Divide the A pieces into two equal piles. For each pile place one piece on a flat surface. Apply white glue and place the next piece on top. Use four 3/4" dowels for alignment. Glue and place until all the pieces is glued in place. Carefully remove the dowels and press with some heavy weight. Repeat this again with the other half of the A pieces. You have completed the A assemblies.

Step 3: Glue B Pieces

Divide the B pieces into two equal piles (This does NOT include the B' pieces). For each pile place one piece on a flat surface. Apply white glue and place the next piece on top. Use four 3/4" dowels for alignment. Glue and place until all the pieces is glued in place. Carefully remove the dowels and press with some heavy weight. Repeat this again with the other half of the B pieces. You have completed the B assemblies.

Step 4: Attach Wings (B' Pieces)

Skip this step if your pony does not have wings. Lay the B assemblies on a flat surface with their noses facing away. Using three dowels for alignment, glue the B' piece on top. For rest of this instructable, these will be referred to as the B assemblies.

Step 5: Join a and B Assemblies

Lay the B assemblies on a flat surface with their noses facing away. For each one take an A assembly, apply glue to its upper surface, tuck it under the B assembly. Carefully remove the four alignment dowels as you apply weight to press them together.

Step 6: Glue D Pieces

Skip this step if you are not making a unicorn or winged unicorn. Start with one D piece and place on a flat surface. Apply white glue and place the next piece on top. Use three 3/4" dowels for alignment. Glue and place until all the pieces is glued in place. Carefully remove the dowels and press with some heavy weight. You have completed the D assembly.

Step 7: Glue C Pieces

Split the C pieces and glue on either side of the D assembly. If you do not have a D assembly just glue all the C piece together. In either case use three alignment dowels and press with heavy weights. Call this the C assembly.

Step 8: Final Assembly

Glue the AB assemblies on each side of to the center C assembly. Use three alignment dowels and clamp after gluing. Assembly is complete.

Step 9: Fluff the Wings and Stand Back

Fluff the wings (if the pony has them) and it is ready for play. You can paint it but kids really like decorating themselves with markers, paint, and glitter.