Creative Inventions and Robotics build-it-yourself

Creative Inventions and Robotics

www.build-it-yourself.com

Laboratory

• This project requires close supervision.

•Anyone who does not follow the tool rules gets immediately benched.

•Soap Box Racers may not be run anywhere near cars.


The Problem:Dirty gas guzzlers are fouling up our air.

The Mission:Your mission is to build a clear air mobile.



Soap Box Racers may not be run anywhere near cars. Our goal is to replace these ugly, gas guzzlers with more intelligent machines. Which car would you want to drive?

Tool Rules

1 Don’t cut your finger off.2 Hold work firmly.3 Wear goggles.4 Think what happens if you slip.5 Clean up.6 “ I Can’t “ is forbidden..


How to ensure your saw cuts are straight.

1. Mark straight, perpendicular lines using a T-square.

2. Position yourself so you can move your saw easily and with leverage.

3. Hold your work firmly with a clamp, or your foot or with the help of a teammate.

4. Make smooth saw strokes. Let the saw do the work.

All the materials you will need are listed at the end of these slides.


6”

6”

Start by mounting wheels on the rear and front axles.

It is recommended that if you are going to motorize your racer, you use 10” wheels or larger with ball bearings. This will give you the best power to drive heavier loads.

Saw 1” x 3.5” pine boards for the rear and front wheel supports. Read the scale on the drawing to figure out how long these boards should be.

Frontaxle

Rearaxle

Use big rear wheels if you want to motorize your racer.


1”2”

1”

Scrap wood to protect from drillinginto the table

5/16” drill bit

Measure and mark locations for drilling carefully as shown. If your measurements are not accurate, your wheels will be crooked and you will run like a turtle!


Drill 4 holes as shown here in the ends of the 2.5’ front axle board and the 1.5’ rear axle board.

5”x ½” lag bolt2” long x 1” wide U bolts


If you can’t find the proper U bolts, you can use 4” metal straps and screw them to the axles.


Or you can use ½” copper pipe fasteners.

To hold the lag bolt securely, use a plastic tube that just fits around the lag bolt.

Alternative Wheel Mounting Ideas

6”

6”

Connect the rear and front axle boards to the main chassis beam.

The front axle will rotate around a 2.5”x½” lag bolt that goes through the front axle and main chassis beam.

The rear axle will be be screwed to the main chassis beam so it cannot rotate.

Cut a 1” x 3.5” pine board for the main chassis beam. Use the scale drawing to figure out how long this board should be.


½” drill bit

2.5’x3.5” front wheel assembly

Measure the exactcenter of the 2.5’ x 3.5” front axle board.

Scrap wood to protect from drilling into the table


½” drill bit

Drill a ½” hole inone end of the 3’ main chassis beamthat connects thefront and rear axles.



Drill ½” holes

2.5”x ½” lag bolt

3’x3.5” main chassis beam

½” nuts (2 nuts tightened against each other will lock them to the bolt.)

½” washer

2.5’x3.5” frontwheel assembly





1/8” drill bit

1.5’x3.5” rear wheel assembly


1.25” sheet rock screw


If any sheet rock screws poke through the wood, immediately put hot glue or duct tape over the screw tips to protect against nasty cuts!!!


Do not ignore this important step.

Always check for protruding screw tips.

They are among the most dangerous parts of this project.

6”

6”

Build the seat back & base.

Cut:3.5” x 18”3.5” x 10”1.5” x 10”Drill 1/8” holes.


6”

6”

Build the steering support.

Cut:3 pieces 3.5” x 10”1 pieces 1.5” x 10”Drill 1/8” holes.


Make the steering wheel.

12”

18”

10”

1.5”

3/4” dowel

Cut and bend coat hanger wire in a circle. WEAR GOGGLES!

Drill a 5/16” hole big enough to thread 1/4” nylon rope.

All other holes should 1/8”

Wrap foam rubber or pipe insulation around the wire and wrap with duct or electrician’s tape.


Make the steering wheel.

Screw a 3/4” U clamp around the 1” steering shaft. Wrap the shaft with foam rubber to keep the shaft from turning.

Turn the steering assembly around and insert a lock screw to keep the shaft from turning.


6”

6”

Screw 3/4” U clamps to the steering support.

Put a ¾” washer on the steering shaft and insert the steering wheel shaft into the U clamps.


Add a ¾” washer on the end of the steering wheel shaft and insert screws to keep the washers in place.

6”

6”

Thread ¼” nylon rope through the big hole in the steering shaft.

Wrap one end of the rope around the steering shaft 5 times in one direction.

Do the same with the other end.


6”

6”

You must cross the rope ends to make the wheel axle follow the steering wheel properly.

Thread the rope through screw eyes on the main chassis beam.


6”

6”

You can buy curtain cleats at a hardware store for $2 each.

Or you can insert screws at an angle as shown below to simulate a cleat.

The cleats must be exactly 10” from the center bolt.


6”

6”

Use a sailor’s cleat hitch knot to secure the rope ends .


6”

6” www.build-it-yourself.com

Add a foot rest and a dash board.

You can mount a break pedal on the foot rest.

Connect the 3.5” x 10” break pedal to the foot rest with a strap hinge.

Insert 2 screws. Add rubber bands as shown to keep the pedal off the ground until it is pressed to stop the racer.

6”

6” www.build-it-yourself.com

Now you have a good basic structure on which to add extra features and decorations.


You must look cool

1. Add a page in your PowerPoint Lab book that advertises the features on your racer. Google how the big boys advertise their cars and see if you can outdo them.

2. Make a hood ornament that moves when you pull a string.3. Build a comfortable seat from your Mom’s softest pillows.4. Make flags.5. Make clever license plates and bumper stickers.6. Decorate a dash board.7. Add flames coming from the back.8. Add sponsor decals.9. Add a cup holder, horn, bell, radio, head lamps and rear

view mirrors.

You’ll need to collect a big box of premium quality junk.


You must look cool

1. Make sure your wheels spin freely and are well aligned.2. Look for ball bearing wheels.3. Reduce weight for downhill drag racing.4. Tighten your steering rope for slalom racing.5. Add weight to increase momentum for distance racing.


You must be fast

1. Best teamwork 2. Best craftsmanship3. Best engineering4. Best looking5. Fastest downhill drag racer6. Most accurate slalom racer7. Longest runner8. Best breaks


Awards

What you should learn

1. 3 Laws of the Lab2. Problem and mission3. Extreme building4. Presenting your ideas5. 5 Tool rules6. Cutting straight7. Problem solving tricks8. Premium Quality Junk:

horn, mirror, radio, lights, license plate, hub caps, front hood logo.



If you think you are a hot shot automotive engineer, you can try motorizing your jalopy.

You should look for wheels that are at least 10’’ radius and that have ball bearings.

If you are a big palooka, you may need two 19V electric drills to pull a heavy load!

6”

6”

electric drill

supportboard

hinges

pedal

rope


Connect the electric drill to the support board with plastic ties. Drill holes in the support board for the plastic ties.

Connect the support board to the frame with a hinge.

6”

6”

electric drill

supportboard

hinges

pedal

rope


After you connect the motor support board and foot pedal to the frame with hinges, then tie a rope from the support board to the foot pedal.

You will need to attach a spring to the support board so the motor is normally not touching the wheel.

6”

6”

electric drill

supportboard

hinges

pedal

rope

Tools, supplies and approximate prices on the following pages are from Home Depot.

If you are clever, resourceful and recycle minded, you may be able to reduce the cost of your racer by more than half.


A few ideas:• Look for wheels on an old baby carriage.• Use a hand drill and screw driver instead of an electric

drill.• Share tools with your buddies and neighbors.• Look for recycled wood.• Use your parents broom stick instead of a ¾” 4-foot

dowel.• Figure out a way to use wood instead of U bolts to

secure the wheel lag bolts.

Half Price ???Half Price ???

Tools from Home DepotTools: Qty Cost Ea Total Cost

Hand saw 1 $ 6.00 $ 6.00 Phillips screw driver 1 $ 3.00 $ 3.00 Pliers 1 $ 4.00 $ 4.00 Battery powered 12V electric drill (RYOBI)

1 $ 49.00 $ 49.00

1/8" drill bit 1 $ 1.50 $ 1.50 5/16" drill bit 1 $ 1.50 $ 1.50 1/2" dirll bit 1 $ 3.39 $ 3.39 Right angle square 1 $ 5.00 $ 5.00 Circular file 1 $ 5.00 $ 5.00 Hot glue gun 1 $ 5.00 $ 5.00 8' Tape measure 1 $ 5.00 $ 5.00 Sand paper 1 $ 3.00 $ 3.00 Total Tools $ 91.39


Prices may change.

Supplies from Home DepotSupplies: Qty Cost Ea Tot Cost Misc Tools and Supplies

Wheels 8"x1.5" Plastic 4 8.99$ 35.96$ 2 plastic milk container boxes for sawing

6" x 1/2" lag bolts 4 0.98$ 3.92$ Cardboard boxes for hood and rear2.5" x 1/2" lag bolt 1 0.65$ 0.65$ Junk for decorations1/2" washers 10 0.15$ 1.50$ Water based paint and brushes1/2" lag bolt nuts 2 0.25$ 0.50$ Foam rubber or pipe StyrofoamU-bolts 1/4v3/4"x1-1/2" 8 0.95$ 7.60$ PencilT LD 2"ZN CD/2 hinge 4 0.50$ 2.00$ Paint tarpolin4' x 3/4" wood dowl 1 2.59$ 2.59$ Extension chord3/4" washers 2 1.50$ 3.00$ Power outlet1/4" x 4' nylon rope 1 2.69$ 2.69$ Plastic sorting containers3/4" copper pipe H fasteners 3 0.90$ 2.70$ 1"x2"x6' pine #2 2 1.55$ 3.10$ 1"x4"x6' pine #2 3 2.35$ 7.05$ 1" sheet rock screws 20 0.05$ 1.00$ 3/4" sheet rock screws 20 0.05$ 1.00$ 1-1/2" sheet rock screws 20 0.05$ 1.00$ Duct tape 1 5.00$ 5.00$ Total Supplies 81.26$


Prices may change.

Supplies for Motorized Racerfrom Home Depot

Same as for non-motorized except add purple rows

Wheels 8"x1.5" Plastic 2 8.99$ 17.98$ 2 plastic milk container boxes for sawing

Wheels 12" Ball Bearing 2 14.99$ 29.98$ Cardboard boxes for hood and rear

6" x 1/2" lag bolts 4 0.98$ 3.92$ Junk for decorations2.5" x 1/2" lag bolt 1 0.65$ 0.65$ Water based paint and brushes1/2" washers 10 0.15$ 1.50$ Foam rubber or pipe Styrofoam1/2" lag bolt nuts 2 0.25$ 0.50$ PencilU-bolts 1/4v3/4"x1-1/2" 8 0.55$ 4.40$ Paint tarpolinT LD 2"ZN CD/2 hinge 4 0.50$ 2.00$ Extension chord4' x 3/4" wood dowl 1 2.59$ 2.59$ Power outlet3/4" washers 2 1.50$ 3.00$ Plastic sorting containers1/4" x 4' nylon rope 1 2.69$ 2.69$ 3/4" copper pipe H fasteners 3 0.90$ 2.70$ 1"x2"x6' pine #2 2 1.55$ 3.10$ 1"x4"x6' pine #2 3 2.35$ 7.05$ 1" sheet rock screws 20 0.05$ 1.00$ 3/4" sheet rock screws 20 0.05$ 1.00$ 1-1/2" sheet rock screws 20 0.05$ 1.00$ Assorted plastic ties 1 6.99$ 6.99$ 19V Ryobi Electric Drill 1 95.00$ 95.00$ Duct tape 1 5.00$ 5.00$ Total Supplies 192.05$


Prices may change. Contact Build-It-Yourself for plans to motorize your racer.

Creative Inventions and Robotics build-it-yourself

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