Creative Inventions and Robotics build-it-yourself

1. Laboratory Soap Box Racer Creative Inventions and Robotics www.build-it-yourself.com

2. Soap Box Racer • 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. www.build-it-yourself.com

3. Soap Box Racer The Problem: Dirty gas guzzlers are fouling up our air. The Mission: Your mission is to build a clear air mobile. www.build-it-yourself.com

4. Soap Box Racer

5. Soap Box Racer 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? www.build-it-yourself.com

6. Soap Box Racer 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.. www.build-it-yourself.com

7. Soap Box Racer How to ensure your saw cuts are straight. • Mark straight, perpendicular lines using a T-square. • Position yourself so you can move your saw easily and with leverage. • Hold your work firmly with a clamp, or your foot or with the help of a teammate. • Make smooth saw strokes. Let the saw do the work. All the materials you will need are listed at the end of these slides. www.build-it-yourself.com

8. Soap Box Racer 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. Rear axle Front axle Use big rear wheels if you want to motorize your racer. 6” www.build-it-yourself.com

9. Soap Box Racer Drill 4 holes as shown here in the ends of the 2.5’ front axle board and the 1.5’ rear axle board. 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! 5/16” drill bit 2” Scrap wood to protect from drilling into the table 1” 1” www.build-it-yourself.com

10. Soap Box Racer 2” long x 1” wide U bolts 5”x ½” lag bolt www.build-it-yourself.com

11. Soap Box Racer Alternative Wheel Mounting Ideas 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. www.build-it-yourself.com

12. Soap Box Racer 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. 6” www.build-it-yourself.com

13. Soap Box Racer Measure the exact center of the 2.5’ x 3.5” front axle board. ½” drill bit Scrap wood to protect from drilling into the table 2.5’x3.5” front wheel assembly www.build-it-yourself.com

14. Soap Box Racer Drill a ½” hole in one end of the 3’ main chassis beam that connects the front and rear axles. ½” drill bit Scrap wood to protect from drilling into the table www.build-it-yourself.com

15. ½” washer ½” nuts (2 nuts tightened against each other will lock them to the bolt.) Soap Box Racer 2.5”x ½” lag bolt 3’x3.5” main chassis beam Drill ½” holes 2.5’x3.5” front wheel assembly www.build-it-yourself.com

16. Soap Box Racer 1/8” drill bit Scrap wood to protect from drilling into the table 3’x3.5” main chassis beam www.build-it-yourself.com

17. Soap Box Racer 1.25” sheet rock screw 1.5’x3.5” rear wheel assembly 3’x3.5” main chassis beam www.build-it-yourself.com

18. Soap Box Racer 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. www.build-it-yourself.com

19. Soap Box Racer 6” Build the seat back & base. Cut: 3.5” x 18” 3.5” x 10” 1.5” x 10” Drill 1/8” holes. 6” www.build-it-yourself.com

20. Soap Box Racer 6” Build the steering support. Cut: 3 pieces 3.5” x 10” 1 pieces 1.5” x 10” Drill 1/8” holes. 6” www.build-it-yourself.com

21. Soap Box Racer Make the steering wheel. Cut and bend coat hanger wire in a circle. WEAR GOGGLES! 10” 1.5” 3/4” dowel 18” Wrap foam rubber or pipe insulation around the wire and wrap with duct or electrician’s tape. Drill a 5/16” hole big enough to thread 1/4” nylon rope. 12” All other holes should 1/8” www.build-it-yourself.com

22. Soap Box Racer 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. www.build-it-yourself.com

23. Soap Box Racer 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” www.build-it-yourself.com

24. Soap Box Racer 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” www.build-it-yourself.com

25. Soap Box Racer 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” www.build-it-yourself.com

26. Soap Box Racer 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” www.build-it-yourself.com

27. Soap Box Racer Use a sailor’s cleat hitch knot to secure the rope ends . 6” 6” www.build-it-yourself.com

28. Soap Box Racer Add a foot rest and a dash board. You can mount a break pedal on the foot rest. 6” 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” www.build-it-yourself.com

29. Soap Box Racer Now you have a good basic structure on which to add extra features and decorations. 6” 6” www.build-it-yourself.com

30. Soap Box Racer You must look cool www.build-it-yourself.com

31. Soap Box Racer You must look cool • 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. • Make a hood ornament that moves when you pull a string. • Build a comfortable seat from your Mom’s softest pillows. • Make flags. • Make clever license plates and bumper stickers. • Decorate a dash board. • Add flames coming from the back. • Add sponsor decals. • 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. www.build-it-yourself.com

32. Soap Box Racer You must be fast • Make sure your wheels spin freely and are well aligned. • Look for ball bearing wheels. • Reduce weight for downhill drag racing. • Tighten your steering rope for slalom racing. • Add weight to increase momentum for distance racing. www.build-it-yourself.com

33. Soap Box Racer Awards • Best teamwork • Best craftsmanship • Best engineering • Best looking • Fastest downhill drag racer • Most accurate slalom racer • Longest runner • Best breaks www.build-it-yourself.com

34. Soap Box Racer What you should learn • 3 Laws of the Lab • Problem and mission • Extreme building • Presenting your ideas • 5 Tool rules • Cutting straight • Problem solving tricks • Premium Quality Junk: • horn, mirror, radio, lights, license plate, hub caps, front hood logo. www.build-it-yourself.com

35. 6” electric drill support board rope hinges pedal 6” Soap Box Racer 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! www.build-it-yourself.com

36. 6” electric drill support board rope hinges pedal 6” Soap Box Racer 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. www.build-it-yourself.com

37. 6” electric drill support board rope hinges pedal 6” Soap Box Racer 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. www.build-it-yourself.com

38. Soap Box Racer 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. Half Price ??? • 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. www.build-it-yourself.com

39. Soap Box Racer Tools from Home Depot Prices may change. www.build-it-yourself.com

40. Soap Box Racer Supplies from Home Depot Prices may change. www.build-it-yourself.com

41. Soap Box Racer Supplies for Motorized Racer from Home Depot Same as for non-motorized except add purple rows Prices may change. Contact Build-It-Yourself for plans to motorize your racer. www.build-it-yourself.com