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Download Ski Rex
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Turn the handle on the Ski Rex and watch our prehistoric friend indulge in a bit of cross country skiing!

This model is actually a mash-up of the double crank box model and the pose-able T. Rex with added skis poles and a bit of colour! I've put all the parts into one file in both coloured and uncoloured form. If you are a member you can download the parts for free at the link. Non-members can download the parts for £2.50



Let's get started!

Print out the pages onto thin card. (230 micron / 67lb) Score along the dotted and dashed lines then cut out the holes before carefully cutting out the parts. There are six sheets in this model.


Start by making the T. Rex

Glue together the four parts that make the body.


Assemble the head upper, gluing the head inners into place (Deep red in the picture) make sure the tabs on the head inners are folded inwards as shown.


Glue together the tongue support.


Glue the tongue support into the assembled lower jaw.

Curve the tongue round and glue it to the tongue support.


The arms and legs are double thickness card. Fold them over and glue them down leaving the tabs unglued. Once the glue is dry, cut out the parts.


Fit the legs into the body. Glue one of the large disks to the leg tabs. Make sure that the leg is free to move as the glue dries.


Repeat this process with the arms. Use the small disks to secure them.


Thread the tabs from the head inner through the holes in the lower jaw and then into the body. Glue the remaining disks over the tabs making sure that the head and jaw can move.


Glue on the eyes and the feet to complete the T. Rex. Set her to one side as you start on the box.


Assemble the two short crank pieces.


Assemble the long centre crank piece.


Fold up and glue down the four push rod ends to make double thickness card. Once the glue is dry cut out the hole and then cut out the pieces.


Roll round and glue down the four pins lining up the edges with the end of the grey area.


Assemble the push rods. Glue the two push rod ends into place and thread the 'Centre' pin through them. Make sure the pin is free to turn.


Glue the long centre crank piece between the two pins. Make sure both push rods are the same way up.


Complete the crank assembly by adding the two shorter crank pieces and the two pins. Make sure everything is as square and lined up as possible.


Fold up and glue down the tabs at the side of the box-top and box-bottom to make a right angled triangle section.

Fit the box-top stiffeners into place next to the slots in the box-top.


Fold round and glue the flaps on the box end to make equilateral triangle tubes.


Glue the top of the box end to the box-top. Glue it to the end opposite the long slots.


Assemble the two slider bars and slider tubes.


Glue the two slider bars as centrally as possible in the two slots.


They should look like this from the top. The slider tubes should be free to move back and forth.


Fit the crank assembly into the box end with the tabs on the push rods facing downwards.

Glue the tabs to the slider tubes. The crease on the tabs should line up with the centre of the slider tubes.


Fit the other box end and the box base into place to close the box.


Fold in and glue down the end flaps to make triangular tubes.


Fold in and glue down the flaps at the other end of the box onto the inside walls of the box.


Assemble the handle in three steps.


Glue the handle into place to complete the box. Once the glue is dry you can check that it is working properly by turning the handle. The slider tubes should move back and forth in oppoite directions to each other.


The skis are made from three layers laminated card.

Glue the three layer of card together. Curve the ends upwards before the glue dries. Once the glue is dry they will maintain its shape.

Let the glue dry then carefully cut out the curved end of the ski and cut off any excess card.


Two skis ready to go!


The skis glue onto the tops of the slider tubes. Turn the handle so that the two slider tubes are lined up with each other in the centre of the slider bars. Glue the two skis carefully into place so that they are centred on the box top. Make sure that the skis don't get stuck onto the box top. Rock the handle back and forth a little as the glue is drying to make sure everything is moving freely. Let the glue dry completely before moving on to the next stage.


The T Rex is glued to the ski by the front of the inside toe only. This allows her to lift her ankle as she skis. With the heel roughly five millimetres from the end of the ski glue the toe down onto the ski.


The poles are glued to the underside of the ski. They must not be glued to the box top. Assemble the two poles. Glue the tab on the end of the pole to the underside of the ski next to the star. Glue the circle onto the underside of the ski so that it is centred under the pole.


Glue the dinosaur hands to the top of the poles


Let the glue dry then turn the handle to see your T. Rex ski. Ski Rex indeed!


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£2.50
Download Double Crank
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Double crank mechanism. Turn the handle on the side of the box and the two pads on the top of the box move back and forth in opposite directions.



Make this project as a way of understanding mechanisms or as the starting point for your own character based paper automata.

Members can download the parts for free from the Add to Basket link at the top of the page. Non-members can download the parts for £2.50

Print out the parts sheets onto thin card. (230 micron / 67lb) The design has no colour in it. To make a colourful model print it out on some pre coloured card. Score along the dotted and dashes lines then carefully cut out the holes before carefully cutting out the parts.


Fold in the box top and box bottom and glue down the side flaps so that they make right angled triangles.


Glue the three box top stiffeners into place. Glue the flaps from the sides of the slots back onto the box top stiffeners.


Glue together the two slider bars and thread the two slider tubes into place. Make sure that the slider tubes are free to move back and forth along the length of the slider bars.


Glue the two slider bars to the underside of the box top so that they are exactly centred in the slots.


Make sure that the slider tubes are free to move back and forth.


Roll up and glue the various pins. Use the arrows and grey areas to make sure that the edges are glue down in the correct place.


Fold over, glue down then cut out the four crank rod ends. Glue two crank rod ends to each push rod and thread the 'Centre' pin into each one.


The completed push rods.


Fold up the long centre crank...


....and glue down the ends as shown.


Assemble the two other cranks in the same way.


Assemble the handle in the three steps.


Join the two push rods together by gluing the pins into the long crank section. Make sure that the two push rods are the same way up, tabs to the bottom.


Finish off the crank assembly by gluing on the two shorter crank pieces and gluing the pins into place.

Make sure that the push rods are free to turn on the pins as the glue dries.


Glue the ends of the push rods onto the bottom surface of the slider tubes. The crease on the tab should be roughly in the centre of the slider tube.


Fold round and glue the triangle sections on the sides of the box end.


Glue the box end to the box top. Make sure you glue it to the opposite end of the box from the two slots as shown in the picture.


Thread the crank assembly into the box end and glue down the box end sides.


Fit the other pieces of the box into place then fold them round to close the box.

Fold in the tabs and glue them to the inside wall of the box.


Fold in the two tabs at the other end of the box and glue them back to back to make a triangular tube.


Finish the model by gluing the handle into place.

Now that you have completed your double crank mechanism it is time to think about how you could add a character to the top of the box. What will you make? A cross country skier? Michael Jackson moonwalking? Two pirates swabbing the deck? It's over to you!



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£2.50
Download Crank Bellows
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Turn the handle on the Bellows Pipe Box to hear the two tone alternate tweeting of the twin bellows powered by the central crank.



The project is free for paid members to download and print out at the link. Non-members can download the parts for £2.50



See the end of the post to see hear the model working.




Print out the parts onto thin card, 230 micron or 67lb
The two bellows need to be printed onto ordinary printer paper.

Score all the dotted and dashed lines and cut out the holes before carefully cutting out the parts.


Fold up the box top and bottom so that the sides are right angled triangles.


Fold up and glue the ends to make equilateral triangles.


Glue the box top and bottom and ends together.


Assemble the two side pieces.


Fold up and make the two crank pieces.


Assemble the crank ends from double thickness card. Carefully cut them out once the glue is dry.

Fit two crank ends to each push rod.


Glue the linkage to the top of the push rod as shown.


Assemble the three pins and the spacer as shown.


Fit the centre pin through the two push rods with the spacer in the middle.

Glue one crank into place on the centre pin


Glue the other crank into place on the centre pin. Make sure that the push rods are free to move.

Fit the two remaining pins into place.


Make up the pipe tubes.

Make up the pipe covers.


Fit the pipe cover into place lining it up with the bottom edge of the pipe and the grey area. You can test the pipes by blowing through the hole in the bottom. Make adjustments as necessary before the glue is fully dry.


Glue the pips into place on the ends of the box lining them up over the holes.


Before making the bellows pre-crease all the score lines to make folding easier.

Roll round the tube and glue it down on the grey areas lining it up carefully.

Fold down the first row of creases.


Work your way down the bellows folding up one row at a time.


Make up the end the bellows end by making it double thickness then carefully cut it out.

Glue the bellows end into place.


Squash the bellows down and glue them to the inside end of the box


Once they are glued in pull the bellows out a bit to inflate them. With the bellows end pulled out glue the tab on the end of the push rod into the centre of the hexagon. Repeat the process at the other end of the box.


Fit the side over the two crank pins and glue them to the grey areas. on the box top and bottom.


Assemble the handle in three steps.


Glue the handle to the side to finish off the model. Wait for the glue to dry completely before trying it out.


Turn the handle and hear the pipes tweeting!

See the project in animated action here.


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£2.50
Download Twitter Bird Box
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The Twitter Bird Box is the starting point for a future Twitter Bird project. It is interesting and fun to make on its own so I thought I would release it as a project in its own right. Turn the handle on the side of the Twitter Bird Box and the double finger cams tap repeatedly on the bellows making the integral pipe tweet.

Members can download the parts for free from the link at the top of the page. The parts are available to non-members for a small fee.

Print out the first three pages onto thin card. I used coloured card to add interest to the finished model. The last page is the net for the bellows. Print this out onto normal photocopier paper.

Score along all the dotted and dashed line and cut out the holes before carefully cutting out the parts.

You can see the Twitter Bird Box working on Instagram here.

Roll the bellows paper round into a tube and glue the edges down. Line up the edges as accurately as possible


Working from one end of the tube fold the creases. Dashed lines are hill folds, dotted lines are valley folds.


Work your way down the bellows tube one row at a time.


The completed bellows


Glue up the pipe tube as shown.


Assemble the pipe end and glue it to the end of the pipe. The bottom edges should be aligned accurately with the bottome edge of the pipe.


Fold over the double hexagon piece and glue it down to make double thickness card. Cut out the marked hole with a sharp knife then cut out the hexagon.

Glue the pipe to the hexagon so that the hole lines up with the air inlet in the bottom of the pipe.


Glue the hexagon to the front of the bellows. Glue the single hexagon piece to the back of the bellows. Once the glue is dried you can test it to make sure it works!


Assemble the two box side pieces with right-angle triangle tubes.


Make up the larger of the two box ends with equilateral triangle tubes.


Glue the ends to the sides... (note the the smaller end piece fits on the end with the faint bellows markings)


Glue the flaps into place making sure that the box is lined up squarely.


Fit the completed bellows into place in the shallower end of the box. Make sure that the bellows are centered so that they don't catch on the sides.


Assemble the cam shaft with double thickness cams. Line up the cams with the two grey lines on the axle.


Roll up the axle and glue it down lining up the edge with the red arrows and the edge of the grey area.


Hold the cam shaft into place and thread the axle inner into place.


Assemble the handle in three steps.


Glue the handle to the axle to complete the model.


Turn the handle briskly to hear the Twitter Bird Box twitter!


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Add to Cart to download this kit for free !
Download Agreeable Sheep

Turn the handle on the Agreeable Sheep and she agrees with everything you say.

"Are you impressed with my cutting skills?" Yes!

"Shall we have a coffee and cake?" Yes!

"Is it time to go home?" Yes!

"Does my bum look big in this?" Probably best not to ask.

The MkIII Agreeable Sheep is now three times as agreeable as previous versions! Turn the handle once and she nods three times powered by the triangular cam concealed in the box base. The model also features a host of improved paper engineering designs from round axle to improved base layout. Ready to start? Yes!

 


The Agreeable Sheep is free for everyone to download. Just click on the link on the top of the page to get started.

There are three sheets of parts. For each sheet, print out the front onto thin card (230 micron/67lb) flip the card over, return it to the printer and print out the back. If you would prefer to choose your own colour scheme there is also an uncoloured version included within the file.

Once the ink is completely dry, score along all the dotted and dashed lines, cut out the holes, then carefully cut out the parts.


We'll start by making the sheep.

Fold up and glue together the head.


Fold up and glue together the body inner.


Glue the body inner into the inside of the body. The front edge corner arrowed here should be approx 3mm above the front edge of the front leg.


Gently curve the body round and and glue it to the other side of the body inner.


Glue the neck into place.


Glue the head to the tab on the neck. The head should now be free to nod up and down.


Assemble the head push rod.


Glue the large tab on the push rod into the head. Line it up so that the crease touches the neck tab.


Now to make the box for the sheep to stand on.

Fold up and glue down the box top. The three triangular tubes should all be right angled triangles.


Thread the push rod down through the hole in the box top. Glue the feet to the marked areas.


Assemble the cam follower.


Fit the cam follower end into place lining up the end with the cam follower front.


You'll need two small coins as weights. UK one pence pieces are the perfect size. (20mm diameter 4gram weight) US$ cent and Euro cent are also a good fit. Wrap a strip of scrap card round the coins and glue it shut. Glue the coin pack to the top of the cam follower.


Glue the cam follower to the front of the box top. Glue the push rod to the other end of the cam follower. If you lift the cam follower with your finger the sheep should nod.


Make the triangular cam by folding over the card piece into double thickness card then, once the glue is dry, carefully cut it out.


Thread the cam onto the cam shaft lining it up with the grey line.


Roll up the axle and glue it down lining up the ends accurately against the five arrow heads.


Fold round and glue down the tabs at the ends of the box front to make triangular tubes.


Glue the box front to the front edge of the box top as accurately as possible.


Thread the axle through one hole, through the cam shaft and out of the other hole. There should be slightly more axle to the right of the box as this is where the handle will fit.


Glue the back of the box to the box top. Don't glue the sides down yet.


Assemble the box base with right angled triangle sides in the same way that you made the top. Glue the base to the back.


Glue the base to the front closing the box. Glue the side flaps front and back, into place.


Fold in the flaps on the front of the box and glue them to the inside of the box walls.


Glue together the tabs in the box back to make triangular tubes.


Assemble the handle in three steps.


Glue the handle into place.


Turn the handle on your completed Agreeable Sheep.

Did it work? Yes, yes, yes!


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£2.50
Download Paper Dancer
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Make this paper dancer driven by a four bar linkage mechanism. Turn the handle and the figure shimmies from side to side Could be a dancer, could be a goal keeper, you decide! Perfect as a classroom project where class members add photographs or pictures oftheir own faces to the character!

Members can download the parts for free at the link, non-members can download the parts for £2.50

 

Print out the parts sheet onto thin card. (230 micron/67lb) Score along the dotted lines and cut out the holes then carefully cut out the pieces. Assemble the box base first. The parts are included in the file, the instructions are here.


These instructions are for the construction of the dancer.

Fold over and glue down the arms to make double thickness card. Leave the two loose ends unglued. Once the glue is dry, cut out the arms.


Fold over and glue down the end tab of the arm inner to make double thickness card. Glue the inner into place.


Glue the link to the end of the arm tab.


Fold round and glue down the body.


Fold over and glue down the end tab on the upper leg to make double thickness card.


Glue the two legs to the body.


The long tabs stick out into the body like this. The legs should be free to move and the hips, knees and ankles.


Thread the arm tabs down through the top of the body and glue the ends to the ends of the leg tabs.


Glue the top body tabs to the inside of the arms.


Fold and glue the body stand. Glue it into the bottom of the body so that only the bottom 10mm or so are glued in.


Assemble the head and neck.


Glue the neck into the body.


Thread the body stand into the open linkage on the box. Glue the feet to the box, one on each side of the hole. Turn the handle and watch the dancer dance!


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£2.50
Download Rockin' Rabbit
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This paper rabbit nods her head driven by a simple pendulum.

Members can download the parts sheet for free at the link, non-members can download for £2.50

The project is on a single sheet and is line only, there is no colour on the parts. I've printed mine out on piece of card preprinted with my recent sprinkles pattern. It also works well with a single sheet of pre-coloured card. You'll need to print out the eyes and tail on white card.

Score all the dashed lines and cut out the parts.


If you are using patterned card, glue a couple of offcuts onto the back of the ears. then cut them out carefully so that the ears are coloured front and back.


Roll round the body and glue it down.


Cut along the two black dart lines to the top of the glue areas.


Fold in and glue down the two darts.


Fold over the arms to make double thickness card ten carefully cut them out.


Glue the arms to the grey areas as shown. The seam on the body is at the back.


Glue together the legs and feet.


Glue the legs to the body.


Make the tail from double thickness card.


Glue the tail to the back of the body.


Glue the neck to the head.


Tuck the neck in and glue it down.


Glue up the nose and glue on the eyes.


You'll need a couple of small coins for this stage. I used UK pennies, one euro cent and one US cent also work well. (20mm diameter 4grams each)


Wrap a scrap of card round the coins and glue it into the bottom of the neck.


Balance the edges of the neck on the edge of the top of the body roughly where the arms are. Move the rabbit slightly and watch her nod!


Try different coloured versions with different coloured card. Have fun!


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£2.50
Download Geneva Mech
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Here's an interesting mechanism for you to download and make. The main handle links to a four-step geneva drive. The movement from this is an intermittent quarter turn rotation which is connected directly to a crank.

The result is this curious motion which can be used as the starting point for your own character based paper animations or made simply as a mechanical curiosity.

Members can download the project for free. Click here to sign up! If you are not a member you can download the parts for this project for £2.50 at the link on the top of this post.

Let's get started.


Print out the pages onto thin card (230 micron / 67lb) Score along all the dotted and dashed lines, cut out all the holes then carefully cut out the parts.


Roll up and glue down each of the four paper tubes. Note that each one has a different number of small triangles. You'll need this to identify the correct tube as the model is assembled.


Join the two parts of the box together.

Inside the box, glue in the two box stiffeners. Glue them as close as possible to the holes with one of the flaps tucked under as shown in the picture above.


Fold round and glue together the box.


Make the Geneva stop from double thickness card leaving the centre tabs unglued.


Fold up one of the two short square tubes and fit it into the Geneva cross. Thread the tube with four triangles into the square tube, lining it up with the end of the square tube. A small dab of glue will hold it into place.


Glue the side piece onto the inside of the drive wheel. Make sure that the square holes are lined up with each other. Repeat the process with the other side.


Roll the drive pin up tightly and glue it down.


Fit the drive pin and short square tube into one side of the drive wheel.


Fit the other side of the drive wheel into place.


Glue the drive wheel side to the tabs at one end of the drive wheel.


Work you way round gluing it down onto the rest of the tabs to complete the drive wheel.


Thread the longest tube (five triangles) onto the drive wheel so that it is lined up with the two grey lines.


Fit the Geneva shaft into the lower hole of the box from the side with the small 'x'


Fit the drive wheel into place next to the Geneva cross pushing it fully home.


Assemble the handle in three steps as shown above.


Glue the handle to the drive wheel.


Assemble the two crank sections as shown.


Fold up the medium length square section tube and slide it over the drive wheel tube.

Glue the first of the crank pieces to the Geneva wheel shaft.


Make up the two pushrod ends from double thickness card.


Glue the push rod ends to the end of the push rod and slip the three-triangle tube in place.


Glue together the remaining section of the crank as shown finishing it off with the short two-triangle tube.


Glue together the three pieces of the cover.


Fold up and glue down the two triangular tubes on the lower edge of the cover. Make sure that they are right angled triangles.


Make right angled triangle tubes from the three top sections.


Glue the cover to the box fitting the drive shaft and crank shaft ends into place.


Fold in the four side tabs and glue them to the inside walls of the box and cover.


Assemble the linkage piece.


Join the linkage to the grey area on the push rod as shown.


And there it is complete. Use the completed model as an interesting mechanism or as the starting point for your own charaacter based automata.


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£2.50
Download Flexibot
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Turn the handle on the side of the Flexibot and the scotch yoke mechanism operates the flex arms. The file for the model parts are available for members to download for free, thanks for signing up! Non-members can join in the fun for £2.50.


The file comes in both coloured and non-coloured version. Print out the parts of your choice onto thin card (230 gsm) The straps that are used to pull the arms need to be printed out onto ordinary printer paper (80gsm)

Score along all the dotted and dashed line and cut out the holes before carefully cutting out all the parts. Follow the instructions below to put together the Flexibot.


Start by gluing together the yoke. Glue the two slider tubes into place, one at each end of the yoke.


Roll round and glue together the five paper tubes lining up the edge as accurately as possible with the points of the arrows.


Assemble the two crank pieces.


Assemble the handle in three steps as shown.


Thread the longest of the five tube through the yoke then assemble the crank parts in situ. The other two tubes are the ones with triangle arrows rather than squares. The crank should be free to move inside the yoke.


Fold up and glue down the tabs on the base of the box parts to make right angle triangle tube sections.


Glue the two parts of the box together.

Slide the two pillars into the slider tubes as shown.

Fit one end of the crank through the hole in the box side.


Fold the box round threading the other end of the crank into the other circular hole.

Glue the box closed.

Glue the two pillars in place using the faint grey arrows for alignment.


Glue the box top stiffener tube to the underside of the box top as shown.

Glue the box top into place on top of the box.


Flip the box over and glue down the two tabs.


Glue the four vertical tabs to the insides walls of the box.


Complete the box by gluing the handle into place.

Once the glue is dry, turn the handle to make sure that the scotch yoke is working properly. The yoke should move smoothly up and down as the handle is turned.


Roll round and glue together the two leg tubes joining then in the middle.


Glue the leg end cap into place.


Glue the six tabs to the inside ends of the legs.


Before you start gluing the arms together fold along all the crease lines to ensure that they flex freely.

Assemble both arms by rolling round each half section and gluing it down. Use the lines and arrows for alignment.


Work your way to the end of the arm.


Thread the long paper strips through the arm and glue the end to the inside top of the narrowest section.

Let the glue dry then try pulling the paper strip, the arm should flex upwards.


Make up the claws from double thickness card.

Fit the claw into the end of the arm.


Glue together the arm holder and thread the two remaining paper tubes into place.


Glue together the two parts of the body and roll them round fitting the arm holder into place with the hole facing downwards as shown.


Glue the body closed.


Assemble the head and fit it into the body top.


Glue the body top into place and glue the eyes onto the head.


Slide the arms into the arm holder carefully threading the paper strips down through the hole and out of the bottom of the body.


Thread on paper strip one through each leg and glue the legs into place in the body.


Thread the paper strips down through the top of the box and glue the legs to the box top.


Turn the handle so that the yoke is at its lowest position.

Pull the paper strip so that the arm is up as high as possible and glue the end of the paper strip to the side of the yoke. Repeat this process with the other paper strip on the other side of the yoke. Let the glue dry.


And there it is complete! Turn the handle and marvel as the robot flexes his arms!


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Add to Cart to download this kit for free !
Download Display Gears

Four interlocking gear wheels in a display case. Art and engineering in perfect harmony.

This project is also on Instructables

The parts of this project are cut out from three millimetre plywood using a laser cutter. In this case, an HPCLaser 3050.

The plans for making this project are available for everybody to download for free. As well as the plywood you will also need a piece of dark coloured paper as a background and a sheet of one millimetre thick clear acrylic for the front of the box. One final addition, you will need three pieces of six millimetre wooden dowel. Two of them twenty four millimetres long and one eighteen millimetres long.

 


The parts file is divided into two pages. The file is a pdf. As different laser cutters use different file formats I leave it to you to convert it to a format suitable for your machine.


The HPCLaser in action cutting out the parts.


All the parts apart for the dowel pieces cut out and ready to go. The blue piece is the clear acrylic front with its protective film still attached. Having cut out all the parts follow the instructions below to assemble the gear display.


Glue together the two eighteen teeth gears. Make sure that they are aligned precisely.


Glue the outer ring to the thirty eight tooth gear as well as the centre hub. Again, make sure you are as accurate as possible with your alignment.


Glue the eighteen toothed gear to the hub. Use a spare piece of dowel to make sure the holes are lined up accurately.


Assemble the twenty two toothed gear as shown using the pentagon hub.


The thirty toothed gear has no hub. Carefully glue the secondary gear ring in place making sure that the teeth are accurately lined up.


Glue together the three base pieces and fit the two longer dowels into place tapping them home with a hammer if necessary. They should be a tight fit and should not be free to turn.


Fit the various spacers into place as shown in the picture.


Glue the eighteen millimetre long dowel into the knurled gear as shown. Make sure that it is sitting accurately square as the glue dries.


Glue the dark backing paper into place. This paper provides contrast with the gears making them stand out visually.


Fit the knurled wheel through the remaining hole in the base plate. It should turn easily in the hole. Fit the small gear into place on the dowel so that it just touches the spacer on the base. It should turn easily via the knurled wheel.


Drop the largest gear onto the dowel. Check that it turns freely via the knurled wheel.


Drop the final gear onto the remaining dowel. Fit the remaining ring over it so that it holds the gear down but still allows it to turn.


Fit together the five main pieces of the frame. Use glue if you need too.


Drop the acrylic front into place inside the box. Glue the two stops into place to hold the acrylic in position.


The finished front cover.


Fit the cover over the gear to complete the project.


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