Cogsworth

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Our objective was to create a model of a prop from one our favorite movies. We chose the story Beauty and the Beast because it was one of our favorite fairy tales from when we were younger.
Coincidentally, there was a movie which was based on Beauty & the Beast coming out in theaters soon.

After deciding what movie we wanted to choose our props from, it was time to chose the one character we wanted to build. In the end, we decided to create Cogsworth because he is one of our favorites from the story. We then had to find a way to incorporate 5-10 LEDs in our model.

This instructable shows how we built a lit up Cogsworth step by step.

Step 1: Resources + Design

Materials :

- 1/8" wood

- 8 LEDs + wires + battery

- Solder

- Hinges

Tools:

- bandsaw

- scroll saw

- wood glue

- rulers

- soldering tools

- paint

- drill

For this project, it was necessary for us to apply our previous knowledge of circuits and cutting wood, all the while researching for new information. We already knew how to work and cut wood, and through the lessons we learned this year, we understood how to use the scroll saw, bandsaw, and the drill. We also knew how to operate and place components on a breadboard. In the beginning, we researched a lot about different things we didn't know, such as how to make LEDs blink and how to solder wires together. In addition, our design process involved us discovering more and more about LEDs and circuits as we worked.

Our main resources were websites and books, for us to learn about the arduino we were initially planning on using. Websites such as these : https://learn.sparkfun.com/tutorials/what-is-an-ar... were helpful for us to learn about how it would affect our circuit and what it was overall. Also, we explored how to make our LEDs blink on http://www.build-electronic-circuits.com/blinking-... but since we were new to the concept of incorporating circuits into figures, we decided not to go that intricate into it.

Our final drawing was a 1 to 2 scale drawing, with measurements and depths. These measurements and depths ended up helping us a lot while we cut pieces and assembled the structure.

Step 2: Planning Out Our Circuit

The circuit consists of 8 LEDs, 8 resistors, a switch and a 9V battery in a parallel circuit. You can use any color of LEDs but we chose to do red. The schematic drawing above shows the parallel circuit with the LEDs, resistors, and switch. The reason we chose to do a parallel circuit is so that if one LED goes out, the others wouldn't.

Step 3: Draw and Cut the First Piece of the Base

Start by drawing out two rectangles that are 28 cm by 4 cm on your wood. Then cut them out on a band saw. Next, draw diagonals that form interior angles of 80 degrees. Afterwards, cut your diagonals. Your two pieces should be trapezoids that are 24 cm on the top and 28 cm on the bottom.

Step 4: Draw and Cut the Arc in Your Base

Now measure 9 cm inwards from each side of your base and draw a line containing the point. Your lines should be 10 cm apart. Using this as a guide for your center, draw out an arc making sure to leave at least 1 cm on the top so it is sturdy. Next, make relief cuts using a scroll saw in the scrap portion of the arc. Finish cutting the arc. Afterwards, make sure to sand out the end result so your arc is left with minimal imperfections.

Step 5: Draw and Cut Out the Face

In this step you need to draw a circle, that has a radius of 9 cm, on your 1/8'' wood. Using a scroll saw make relief cuts that will help you cut out the circle. Next, finish cutting out your circle and sand out any imperfections.

Step 6: Finish the Face

For this step you need to find a good diagram of Cogsworth's face. It is really your preference with what picture you want to choose. We found it easiest to use ..and make sure it was the right measurement. Just make sure it is a little smaller than the size of the circle that was previously cut out for the face. Next, print it out, cut it, and using wood glue, glue it onto the already cut circle. Now trace out the paper's outline and trim the excess wood using a scroll saw.

Step 7: Draw and Cut the 1st and 2nd Part of the Body

Draw two identical pieces in the shape of trapezoids on 1/8'' wood with the top base as 14 cm and the bottom base as 21 cm. Cut the two pieces out on the scroll saw. Afterwards, draw the inside portions by drawing a section that is 3 cm in length on the top center portion of the pieces. Then make three equal curves(each one being about 2 cm in length) as shown in the picture above. Next, trace the shape you have just created below but little longer. Extend the edges so that if you drew a line on the top of the curves, it would be 9 cm. Next, 12 cm downwards of that line draw a line that is 10 cm long. Connect the two with diagonals. Cut this shape out with a scroll saw by drilling a hole in the middle and inserting the scroll saw bad through the whole. Sand any imperfections.

Step 8: Drill Holes for LEDs and Switch.

For this step you need to find a drill bit which is the same size as the LEDs you will be using. If it is too big the LEDs will fall out and it is too small the LEDs won't fit. After you find the correct sized drill bit, drill 4 holes on each side of the front body piece. Make sure to evenly space them out. For the switch you will need a bigger drill bit that will allow the nut and bolt to go through too. After you find one that will fit, drill a hole in one of the depth pieces for it.

Step 9: Assemble the Base Completely

Now, the two rectangular piece that has been made earlier to lay on top of the base finally comes into use. Using wood glue, glue the rectangular block and the bottom part of the base together using your fingers to ensure an even application. Then, when the glue has dried, drill two holes into the new base. The holes should be drilled six cm away from the base. (One should be on the left and the other should be on the right). Afterwards, hammer a nail in each of the two holes; this creates base your base is sturdy.

Step 10: Assemble All Pieces by Gluing

Using wood glue, glue the front piece to one base piece so the body overlaps the base a little and then do the same with the back of the body and the other base piece. It is recommended that you use your fingers or a skewer to evenly apply and spread the glue. Make sure that the body is just above the curve of the base. Do the same with the backside.

Step 11: Cut and Glue Depth Pieces

Now you have to fill in the gaps with the width of the model. All the pieces in this step will be cut from 1/8'' wood. The two bases should be 6 cm apart from each other. So cut out two congruent pieces that are 6 x 4.5 cm, by using a band saw. These rectangular wood pieces serve as the diagonal depths for the base. Now, cut out two 6 x 3 cm wood pieces out from thin wood by cutting them out by using a band saw as well. Furthermore, cut two 6 x 7 cm rectangular pieces from thin wood with the band saw. Paste these pieces in their appropriate areas.

Step 12: Glue Head and Cut/Attach Connections

To attach the face just evenly apply wood glue on the bottom curve of each piece of the face (front and back) and paste it so it overlaps the body a little but not enough to cover the design. Next, to add connections you need to have to cut 5 congruent rectangular pieces from the 1/8'' plywood that you will use as support between the front and back of Cogsworth's face. Originally, we decided to make more congruent pieces so there would be no gaps and the whole cylindrical shape would be surrounded, but due to time constraints we realized that if we evenly space the connections out they still act as support for the face of the prop but it would not look as good. Each piece of plywood should be x cm.

Step 13: Draw and Cut Out the Arms

Create two arms by drawing them first on the thicker piece of wood in the bill of materials. The arms should be five cm long and the widest part width, they should two and one half cm wide. Draw the two arms individually and cut them out by using a scroll saw. To even out any rough edges, use a dremel tool.

Step 14: Make a Box and Door for the Placement of the Battery

Now to integrate the circuit, you need to make a door to a box where you can put your battery. We made a mistake and only cut a piece from the back piece before assembling the rest of our prop. Then we traced, cut, and attached the door after assembling our whole prop. To avoid the challenges we faced through our error in judgement, you should take the back piece of the body and measure a 6'' x 4'' rectangle. Cut the box out so there is a rectangular hole in the back. Now, take another piece of 1/8'' ply wood and trace the rectangle space out. This rectangle should be no bigger than 6'' x 4''. Next, using a band saw cut out the rectangle carefully. See if the rectangle fits in the hole. Sand accordingly. For the next part you need small hinges and screws. First, place the rectangle inside of the whole in the back piece on a flat surface. Place out where you would put the hinges. Make a dot where the screws will go using the guides on the hinges. Then you want to use a drill bit that is just a little smaller than the scores you will use. Drill where you made your pencil markings. Now, place the hinge and using a screwdriver, insert the screws in place into the back piece first. Follow with the door. Your door should open and close perfectly. If the door doesn't fit into the space perfectly you can sand it accordingly.

Step 15: Soldering With Parallel Circuits

With the holes that were drilled on the front of the project, we will insert the glowing LEDs that we will be creating. We created a parallel circuit with a three way branch that included switch. For this step you already have your circuit ready to go. All you need to do now is take it out and solder each connection. Make sure you solder evenly and in a thin coat so it is not to clumpy. We ran into difficulties while soldering because three of our soldering connections broke the after we did them. To avoid this, make sure to use good soldering technique. Also, make sure to use long wires between the parallel connections because if you don't the LEDs may not reach the holes. Additionally, make sure to check each parallel connection before and after you solder them to avoid making the whole thing and realizing that one of them is not working. But since this is a parallel circuit, if one stops working the rest will still light up. After you are done soldering and everything works, place the batter in the box that you previously made for it and put the LEDs and the switch in their designated holes. If you have problems and they are not holding in place you can use electrical tape to secure them.

Step 16: Reflecting Our Work

What we liked best about this project was how we were allowed to use our creativity and thought process to independently decide what we were going to create. Through teamwork, we were able to efficiently make this structure and use our different ideas to compromise. This understanding led to much progress throughout the past two months. For this project, we were able to use different resources available to us, and different materials and assembly methods.

Although we appreciated each other's ideas, we could have made the holes bigger for the LEDs and made the lighting more apparent. We could've added a few more pieces to this design too, but we didn't get the time to because of our time constraints. Also, soldering circuit was a hardship for us, so we could have spent more time on that, before painting. We basically had trouble with organization and time management, but overall, this was a good experience for us to learn about each other and work together to create a complex structure like this using our separate unique skills.

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Discussions

That's really cute :) I'd like to add some acrylic panels in and mount moveable clock hands.