Wooden toys are great for play with. In this instructable I debut the necessary steps in creating a wooden toy.
Step 1: Step 1: Gather Your Materials
Band-saw, for cutting out template and toy. Drill press for drilling axle holes. Drill bits, You will size it in a future step. 1" belt sander for sanding the toy. Router table with 1/4" round over bit. Safety Equipment Supplies 1.25” Axles and Wheels Wood Glue Paint 2” x6” stock ⅛” Cutting Template
Step 2: Step 2: Find Photos of Elephants
On the internet search up pictures of Elephants and find some base example images.
Make sure the trunk and features are visible.
Step 3: Step 3: Print Your Image.
After you find your image download it. Drag it into Microsoft Word and resize it to a size you would like it to be. It’s a children's toy thus it should be a good size for a child. It shouldn’t be too small or too big. Then print your image
Once you find the size of your liking, print out the paper then cartoonize the elephant to be easy to recognize. For example, exaggerate the trunk the and the ears. Then map out where you plan for the holes to be.
Step 4: Step 4: Create Your Template.
Once you have your template cut out of your paper. Trace it onto the 1/8" plywood. This will be a much sturdier template that won't rip or move. when you trace your toy. It also is a lot easier to make multiples with a sturdy temple.
Step 5: Step 5: Cutting Out Your Toy
1. Trace your template onto your stock.I use scrap 2x6 for my toy.Trace as close to the edge of the stock as possible. The less you have to cut the better. 2. Once your template has been traced onto the 2x stock. Cut it out on your band saw. 3. Once you have your toy cut out: Use the paper template where you have marked your axle to mark them on your cut out toy blank. Use a pencil to poke through the paper image and leave a mark it on your toy blank. Make sure the marks on your toy blank are visible.
Step 6: Step 6: Drilling the Axle Holes.
1. Use your axle to find an appropriate drill bit size.
2. Then find the appropriate drill bit. 3. Use a punch or something similar to make a dent in your blank. This will help it so that the drill doesn't walk. 4. Place a scrap piece of wood under your toy and above the drill press table. This will keep your toy from tipping and binding to the drill bit. If it does it will spin out of control and possibly fly at you face. 5. Drill your axle holes through your toy blank.
Step 7: Step 7: Router the Edges
Round over the edges so that the toy will be smoother. Place the round over bit into the router table and make sure the edge of the bit is level or slightly lower than the edge of the table. Test the router bit on a scrap piece of wood first. Adjust the height of the bit as necessary. Router the entire outside of your animal. If there are too small of edges you will need to sand it by hand.
Step 8: Step 8: Sanding Your Animal.
Sanding is just getting the tool marks out from the previous tool.
1 Sand all of your sanding marks out. Work your way up through the sandpaper starting at 150 and going to at least 220. 2. Before moving on make sure that all of tool marks and imperfections are dealt with.
Step 9: Step 9: Paint Your Toy.
First, create your painting plan. Remember this is a wooden toy so keep the wood visible. But painting allows you to be creative and do designs or even make your animal more recognizable.
Step 10: Step 10: Glue in Your Axles and Attach Your Wheels
Check to make sure your axle fit snugly into the axle hole. If you need to drill them out again then do so.Place a small amount of wood glue in the axel hole. Put the glue in the axle hole! Not on the axle. You want your wheel to spin! Put the axle through the wheel. Put the axle and wheel assembly into the glued hole. Make sure to put some space in between the main piece and the wheels. This will allow it to spin.
Step 11: Step 11: Finished!
That is how you make a wooden toy that looks like a elephant.Make sure there is no sharp edges that can cut someone. Also Make sure that there is no splintery spots so kids can get splinters.