PDA

View Full Version : Wooden Toy Cars - Another college design project gone oh so wrong...


pw_cc_runner
11-08-2009, 10:17 PM
Well BCM... I was at it again. I managed to convince yet another professor and had a partner on board this time that a car related project would be a good idea! This project was titled "Wooden Toy" and required us to design a wooden toy with six or fewer unique parts that when pushed, pulled, or wound moved in some way. We also had to produce three of our finals models to get us to think about "mass" producing and how to design it to be "easy" to make multiple iterations of and this was the result:

1 - Body (4 sheets of plywood glued together)
2 - Engine Block (square openings glued into body)
3 - Front Wheels (Two pieces to create wheel appearance)
4 - Rear Wheels (1/4 inch wider than fronts)
5 - Cams (two per car turned opposite to fire pistons)
6 - Pistons (movement based on cams)

Week One:
Basic Shape Concept Sketch:
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1131448298704_1602150071_30325899_7833047_n. jpg

Foam Core Model:
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1131449138725_1602150071_30325909_1385395_n. jpg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs004.snc3/11169_1131449178726_1602150071_30325910_7666332_n. jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1131449098724_1602150071_30325908_2031193_n. jpg

We finished the foam core model at 6:15 AM and it was due at 9 AM. At this point, I think the professor thought we had something really good going, but wanted to rip on us to keep us motivated because he was really really hard on the model. Even though we were exhausted, we took it in stride and worked with his recommendations.

Week Two:
Parts Production:
http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1131445898644_1602150071_30325890_3986179_n. jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1133067459182_1602150071_30330852_7158887_n. jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs024.snc3/11169_1133067499183_1602150071_30330853_1962068_n. jpg

Due to the fact that our studio shop only has 4 band saws and 2 scroll saws we decided to take a trip home to take advantage of the water jet (who wouldn't right? 9 hours of driving, but still way less of a pain), which cuts plywood extremely well. The plywood pieces were then lightly sanded and the bodies were glued together on the alignment dowel pins.

Week 3:
Body Work:
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs004.snc3/11169_1133862479057_1602150071_30332219_5247225_n. jpg

Paint:
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1135631923292_1602150071_30335883_257378_n.j pg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs114.snc3/16143_1135632203299_1602150071_30335890_1949337_n. jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1135632403304_1602150071_30335894_954666_n.j pg

This kid from class being like "WTF you guys are making us all look stupid compared to your projects"
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1135632123297_1602150071_30335888_3989919_n. jpg

Detail Paint Work in Windows and Grill:
http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1136234458355_1602150071_30337928_5710628_n. jpg

Wheels on, Pistons Installed, and Ready to Roll:
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1136234778363_1602150071_30337935_1649586_n. jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1136234858365_1602150071_30337936_7268689_n. jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs114.snc3/16143_1136248938717_1602150071_30338009_5620663_n. jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1136249018719_1602150071_30338011_5824400_n. jpg

It was three weeks of absolute hell with some extremely long hours, but I'd say the end result was well worth it. I still need to pick up some satin black vinyl for the front and rear windows, but otherwise they are mostly complete. Each car was covered in body filler, sanded, primed and sanded three times, and then painted with three coats of color. Our goal was to have them not look like plywood and I would say they certainly do not anymore. Hope you all enjoy checking them out as much as I enjoyed making them while balancing two midterms, a paper, three drawing projects, three short weekly writing assignments, and about 500 pages of reading. No wonder I did not get much sleep...
Reverend Cooper
11-08-2009, 10:49 PM
that is pretty cool
MoCkiN U
11-08-2009, 11:23 PM
wooden model is not nearly as impressive as the foam one although its nicer painted.

That one shows the amount of thought and engineering it took to pull of that working model. Thats some skills right there
pw_cc_runner
11-08-2009, 11:31 PM
wooden model is not nearly as impressive as the foam one although its nicer painted.

That one shows the amount of thought and engineering it took to pull of that working model. Thats some skills right there

Both the foam and the wooden models are fully functional. Why is the foam one more impressive? Just the fact that we worked it all out in crappy foam core or something else?
MoCkiN U
11-08-2009, 11:52 PM
no no not hating. just saying that to pull off and show the planning in a functional foam model is showing some serious planning and layout with each layer put together to form the shape and the cutouts of some layers to form the openings and not in others. The wooden versions even functional hide the beauty and the skill in the finish work of what you actually created. my dumb ass would look at the finished product and not know the depth of what it took to create each layer piece and put together like a rolling puzzle. WOuld almost think was cutout on a cnc machine versus what you actually did. Thats why I like the foam one more. You can see each step clearly and its a work of art
johnny--2k
11-09-2009, 12:25 AM
thats awesome man!
michelle
11-09-2009, 06:10 AM
Very cool!
0TransAm0
11-09-2009, 06:38 AM
they all look good. does the teacher know you guys used a waterjet?
pw_cc_runner
11-09-2009, 07:59 AM
no no not hating. just saying that to pull off and show the planning in a functional foam model is showing some serious planning and layout with each layer put together to form the shape and the cutouts of some layers to form the openings and not in others. The wooden versions even functional hide the beauty and the skill in the finish work of what you actually created. my dumb ass would look at the finished product and not know the depth of what it took to create each layer piece and put together like a rolling puzzle. WOuld almost think was cutout on a cnc machine versus what you actually did. Thats why I like the foam one more. You can see each step clearly and its a work of art

Never thought you were hating, just wanted you to clarify. I though that's what direction you were going in but I wanted to hear your reasoning.


they all look good. does the teacher know you guys used a waterjet?

No he does not, however, its use did not enhance the capabilities of the design. It was more of an excuse to go home and save us some time fighting for a saw. The assignment was not about learning how to use a band saw so I am not concerned.
pw_cc_runner
11-09-2009, 07:00 PM
Got the final touches on them today. We cleared up issues with the functionality of the red car which was binding a little and gave all three cars windshields and rear windows

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs114.snc3/16143_1136780191998_1602150071_30339516_5692849_n. jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs094.snc3/16143_1136780272000_1602150071_30339518_2543948_n. jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs114.snc3/16143_1136780352002_1602150071_30339520_8071782_n. jpg

I cannot wait to turn these in on Wednesday. It will be such a relief but sad as well because it was such a fun project. Thanks for all the complements!
Waver
11-09-2009, 07:09 PM
Dude that is so cool....If I had kids I would buy one. What was the total build costs?
pw_cc_runner
11-09-2009, 07:15 PM
Dude that is so cool....If I had kids I would buy one. What was the total build costs?

For all three including gas, three different thicknesses of plywood, dowel rods, glue, sand paper, body filler, masking tape, black vinyl, primer, and paint... about $175. :rolf
Waver
11-09-2009, 07:54 PM
not bad, take out the gas and you have what? like under 50 bucks a car?
pw_cc_runner
11-09-2009, 08:12 PM
not bad, take out the gas and you have what? like under 50 bucks a car?

yeah actually, about $40-45 each not including running the machine.
jbiscuit
11-09-2009, 08:38 PM
very cool project!!
Z28Envy
11-10-2009, 12:23 AM
Very cool! Nice work.
lilws6
11-13-2009, 08:13 AM
i'll take two please lol those look real cool nice project
Flicktitty
11-13-2009, 08:17 AM
when do you get graded on this?

looks awesome btw.
pw_cc_runner
11-13-2009, 08:40 AM
when do you get graded on this?

looks awesome btw.

We just handed them in on Wednesday, unfortunately the rest of the class was not nearly as ambitious as we were so next to no one had them finished on time or done very well for that matter. They are supposed to have them handed in by Monday at the latest, so I would guess after Thanksgiving.
xxtremeteam
11-13-2009, 08:50 AM
Looks good Josn I am surprised you did put flames on them
pw_cc_runner
11-13-2009, 09:06 AM
Looks good Josn I am surprised you did put flames on them

I would've but time was a major issue so we decided simple was best.
pOrk
11-13-2009, 09:13 AM
45 bucks each? Not very cost effective, after you add machine time your in close to 60 each I bet.
pw_cc_runner
11-13-2009, 01:24 PM
45 bucks each? Not very cost effective, after you add machine time your in close to 60 each I bet.

Well obviously there are more effective ways it could be produced, but with time constraints, hand production, and low production numbers cost going to be increased. These were not designed to be marketed and many aspects of them were extremely over done. We bought our own plywood rather than using what was provided because it was shitty roofing grade wood and instead we used a nicer birch. We also over did it on filler, primer, and paint in an attempt to get the best surfaces possible. Stuff like that would not be considered for a normal bang around kids toy most likely.

They are still art projects first... toys second.
pOrk
11-13-2009, 02:04 PM
Good point. You should have hired cheap Mexican labor like GM, FORD, and CHRYSLER do to get your costs down.
lordairgtar
11-14-2009, 01:14 AM
From design to prototype to functional samples in differing colors, 60 bucks a car is cheap. The cost can be lowered in a production scenario. I could actually see these sold at a place like the Learning Tree or something like that, even as simple assembly kit. Maybe a cheaper plastic version for day care and children's hospital situations (easier to be cleaned and disinfected).