This toy pattern includes a multi-page PDF. Please be sure to download and print the attached toy pattern at the bottom of this page along with these instructions.
Tools
- Table saw
- Band Saw or Scroll saw
- Sanders – Disc, Belt, and spindle
- Router with a chamfer bit
- Drill Press
- Sand paper or emery boards
Material
- 3/4″ x 5-1/2″ x 24″ lumber
- 1/2″ lumber
- 1/4″ dowel
Instructions
- Make pattern from print of the Clown and the Parallel Bar by gluing to a piece of cardboard. Cut pattern to shape. Draw shape on wood surface and locate drill center.
- Make a mirror image of the clown on a copier for use in painting the back side of the clown cut out.
- First cut out the clown from the 24″ board. See the cutting diagram to see how the clown is nested between the parallel rails.
- Plane the remaining portion of the board to 1/2″ thickness.
- Saw the board to the dimensions shown for the base.
- Chamfer the edges of the base as shown.
- Rip the remaining piece of 1/2″ stock to create two equal halves. Using double faced tape, stick the pieces together, aligning the edges and ends. Trace the pattern of the Parallel Bars and saw the parallel bars from this assembly.
- Sand the curved surfaces of the parallel bars and separate the two pieces.
- Drill 1/4″ holes in the base for the parallel bar supports. Provide a piece of scrap wood behind the bars to prevent breakout.
- Drill a 1/4″ hole in the clown for the dowel that allows the clown to rotate and run along the parallel bars.
- Cut 4 pieces of 1/4″ dowel for the parallel bar supports and one 6″ piece for the clown to rotate on the parallel bars.
- Slightly taper the ends of the dowels.
- Glue the clown at the center of the 6″ dowel. Glue the 4 other pieces of dowels into the base and the parallel bars to support the parallel bars above the base.
- Sand to ease rough or sharp edges.
- Rub your hands over the entire vehicle to make sure there are not sharp edges or points. Remove with sandpaper if any are found.
- Paint the clown as indicated on the plan.