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.

Comments

[dhaykus0418]

Why do the 48 pieces need to be "lamented" together? Have they all died or ceased to exist in some way? Perhaps it would be better that they be "cemented together"?

Cool project though.

[dave.vaness.79]

I went back and fixed the problem. That's the problem with dyslexia is that if the misspelled word is a real word you doesn't get caught by the spell checker. I believe you were being flip when bringing up this mistake but people who create do not like to be publicly corrected by people who edit, I spent a good week developing this idea. In the future it would be more appropriate to sent a private message when you find an error.

[dhaykus0418]

It wasn't meant to be malicious in any way, I just thought it sounded very humorous given the context. I really do like the instructable and can't wait to try it as soon as I can get some time on the laser at my local TechShop. I have a niece who would love it.

Thank you.

[dave.vaness.79]

No harm, no foal and lord knows I have bought my share of flowers to cover some clever remark I made. So which pony will you be making?

[dhaykus0418]

Was thinking about the winged pony version, I'll have to get an adequate supply of decent cardboard first. I've started checking
some of the sources that were mentioned above.

Thank you.

[dave.vaness.79]

I just came back from a cardboard run, I talked to the supervisor at a housing tract construction site. I arranged to be there when the installation team removed the cabinets from the boxes They tossed the boxes out the front of the house and I cut what I wanted and threw the reat in the dumpster. Got enough for two ponies. They saved time not breaking down boxes.

[Riffifi]

nice addition to the previous instructable :)

another good source of huge and thick cardboard packaging i found, was a shop for medical equipments (like wheelchairs, medical bed). the owner was happy to give me as many as i could take away. (actually i used them to wrap my big ikea furnitures and stuff before to move to a new home).

[dave.vaness.79]

Thanks That is a great source, I imagine the cardboard on such boxes would be nice and thick.