By: Jon Trussell
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Step 1: Step 1: Gather Your Materials
1. Band saw, for cutting out template and toy.
2. Drill press for drilling axle holes.
3. Drill bits, you will size it in a future step.
4. 1" belt sander for sanding the toy.
5. Router table with 1/4" round over bit.
6. SAFETY GOGGLES!!
1. Axles and wheels. I used 1.25" wheels and axles from the hobby store.
2. Wood Glue.
3. Paint. Depending on the design of your animal.
4. 2"x6" stock (or scrap). To cut your animal out of.
5. 1/8" ply or MDF for cutting template. You could even use card stock or cardboard.
Step 2: Step 2: Choose an Animal/Find a Photo
First make sure you know what animal you want to create. From
there you will search the internet for a side profile picture of the animal. Make sure that the animal is easily recognizable from the side view with the minimum paint required to be able to tell.
Step 3: Step 3: Print Your Image/Create Your Template
Once you have your image, make sure
it is a reasonable size (should fit in a child’s hand) then print it out. Next when drawing your image it should be “cartoonized”. For example: exaggerate the special features of the animal and make it easier to cut out.
Now is an important time to think about what you might add to your toy, like what will be painted, or will it have a tail or piece added to the wood after or before the paint? Make sure to create a place (usually just a mark) that demonstrates where your axles will go.
Step 4: Step 4: Cutting Out Your Toy
First trace your template drawing onto your block of wood. Next use the band saw to cut as close to drawing as possible, the less wood the better. Once your toy is cut out, line it up to your template image, and poke out a hole, after mark where your axle holes will go.
Step 5: Step 5: Drilling the Axle Holes
Make sure to find an appropriate drill bit size, once you have the size find a drill bit.
Always have a piece of scrap wood underneath your toy and above the drill bit table, this will prevent from tipping and ensures safety.
Drill the axles through the toy blank.
Step 6: Step 6: Router the Edges
Place round bit over router edge and make sure edge is level to table.
· Test router bit on scrap wood to ensure that it is ready.
· Round the entire outside of the animal to the best of your ability. This will allow for the toy to be smoother.
Step 7: Step 7: Sand the Animal
When sanding you want to start with the lowest grit, preferably 120 or 100. Work your way all the way up to at least 240. Make sure that all of the imperfections and tool marks are dealt with and the toy is smooth.
Step 8: Step 8: Paint Your Toy
When painting you can have as much artistic design as you want, adding as much or as little as you want! Pro Tip: To draw out your image before so that you have an outline when painting
Step 9: Step 9: Glue in Axles/Attach Wheels
Make sure that the axle fits in your holes! If not you can redrill the holes.
· Place a small amount of glue in the hole (NOT ON THE AXLE)
· Put the axle through the wheel
· Put the axle in the hole leaving enough room so that your wheel will spin
· Give it some time to dry
Step 10: Step 10: You're Done! Enjoy Your Completed Project
This project was assembled in only a couple days, with multiple tools being used to create the best product