Introduction: Wooden Tunnel for Thomas the Tank Engine Playsets
I thought I would write up a quick second instructable for another playset I made for my sons' Thomas the Tank engine track. Unfortunately, I did not document the build of this toy while making it, but a lot of the cutting is freehand and I have done some sketches to give you an idea of the process I used.
My son is a huge fan of tunnels and one of his favourite Thomas episodes has a haunted mine in it, so I decided to us that as the basis for the first playset I built for him.
Again, I used basswood on this project because it is cheap, easy to work with, light and is safe for little hands.
My son is a huge fan of tunnels and one of his favourite Thomas episodes has a haunted mine in it, so I decided to us that as the basis for the first playset I built for him.
Again, I used basswood on this project because it is cheap, easy to work with, light and is safe for little hands.
Step 1: Materials Needed
Tools Required:
Band saw, Scroll saw, Jig saw or Coping Saw
Sandpaper (100 or 120 grit is fine)
Clamps
Drafting Compass (or something round with a 2" diameter)
Pencil
Square
Materials Required:
Basswood 28" x 4 1/2" x 1/2"
Acrylic Paint and Varnish
Brushes
Fine Sharpie Marker
Wood Glue
Brown Paper bag
Old Toothbrush
Band saw, Scroll saw, Jig saw or Coping Saw
Sandpaper (100 or 120 grit is fine)
Clamps
Drafting Compass (or something round with a 2" diameter)
Pencil
Square
Materials Required:
Basswood 28" x 4 1/2" x 1/2"
Acrylic Paint and Varnish
Brushes
Fine Sharpie Marker
Wood Glue
Brown Paper bag
Old Toothbrush
Step 2: Layout and Cutting
The tunnel consists of 6 pieces stacked and glued, but really the most important ones are the front and back as these are the tunnel entrance and exit. measure up 1 3/4" from the long edge of the board, about 6" from the end and draw a 2" diameter circle at that point and cut that piece out. Once the entrance is cut, freehand cut a rolling random arch shape around that line not closer than about 1/2" away from the door cut (see piece #1 below). Next make an even larger rolling random arch shape leaving approximately 1" of material (see piece #2 below). The next piece is the tricky one, as you want to make sure that you overlap the seam between piece #1 and #2 more or less evenly so you can stack and glue them, the second image below can give you an idea of how to cut piece #3. Now, take your first 3 pieces and use them as templates to make a duplicate of each (or you can cut 3 totally different ones using the same procedure if you wish).
I then used the scrap offcuts to make a small sign and more rocks and trees to decorate the haunted mine tunnel.
Then give everything a good sanding and you are ready to paint.
I then used the scrap offcuts to make a small sign and more rocks and trees to decorate the haunted mine tunnel.
Then give everything a good sanding and you are ready to paint.
Step 3: Painting and Finishing
Start by giving all the pieces a coat of varnish, let them dry as per the instructions and then polish them with a crumpled up brown paper bag. The bag acts like soft fine sandpaper and give the pieces a nice feel.
At this point I glued all of the cave layers using a light even coat of glue and clamping them together for about 20 minutes.
For painting, I started by giving the bottom and entire interior of the cave 2 coats of black paint, then applied a light gray coat to all of the 'rock". Next I used a very dry brush with a tiny bit of darker gray paint on it and dabbed it along the bottom edge and in all the nooks and crannies.
Then using the toothbrush, I splattered the whole thing with very watered down white, medium gray and black paint. After the splatter layer has dried, apply two more coats of varnish, giving a paper bag polish in between. (Don't shake your varnish, roll it on a table to mix it... shaking it will give you bubbles in your finish)
Lastly, I glued on the Trees, sign and other details, clamped lightly using scrap wood to protect the finish and let it dry overnight.
At this point I glued all of the cave layers using a light even coat of glue and clamping them together for about 20 minutes.
For painting, I started by giving the bottom and entire interior of the cave 2 coats of black paint, then applied a light gray coat to all of the 'rock". Next I used a very dry brush with a tiny bit of darker gray paint on it and dabbed it along the bottom edge and in all the nooks and crannies.
Then using the toothbrush, I splattered the whole thing with very watered down white, medium gray and black paint. After the splatter layer has dried, apply two more coats of varnish, giving a paper bag polish in between. (Don't shake your varnish, roll it on a table to mix it... shaking it will give you bubbles in your finish)
Lastly, I glued on the Trees, sign and other details, clamped lightly using scrap wood to protect the finish and let it dry overnight.
Step 4:
You may notice that my arch only has 5 layers to it instead of 6, as this was a modification i thought of afterwards, but it works fine either way.
It has been a month in the tender hands of a toddler, and even with daily use (and the dropping and the banging that accompanies belonging to a 3 year old) it has held up surprisingly well. In total this project cost around $5 in stock and about 3 hours of time, so a pretty decent investment.
It has been a month in the tender hands of a toddler, and even with daily use (and the dropping and the banging that accompanies belonging to a 3 year old) it has held up surprisingly well. In total this project cost around $5 in stock and about 3 hours of time, so a pretty decent investment.