Overview and Background

Instructions

This is a laser-cutter project, which will require a supply of acrylic sheet and a laser cutter able to cut at least 1/4" (5.6mm) acrylic.

This model requires several parts to be solvent-welded together after cutting (which is best done using very fast-drying, low-viscosity acrylic solvent cement). The plans include a gluing jig, but with care this is not necessary. Refer to the assembly video at http://mechanicalgifs.com/instructions to see how the glued parts are assembled. (They come pre-glued in the kit being shown, but the video makes clear how they go together.) The two gears requiring gluing have an engraved ring that defines the position of the clutch ring. Peel the protective film from inside the ring, then glue the clutch ring in place, then peel the remainder of the film.

There is one potentially hard-to-find part: 1/4" plastic square tube, used to make the square section of output shaft. It should be possible to make this part in several different ways if the required part can't be found.

The model can be made entirely of plain clear acrylic, or various parts (noted in the plans) can optionally be made of colored acrylic.

The included dxf file contains all the cutting and engraving patterns, one layer per thickness/color of acrylic. Lines in yellow are meant to be engraved, all other colors of line should be cut. Use the speed and power settings appropriate for your laser cutter: every one is different.

The layers are split up by type of acrylic.

A3 should be cut in 1/8" (3mm) acrylic
A3G should be cut in 1/8" (3mm) acrylic, recommended to be colored green
A5P should be cut in 1/4" (5.6mm) acrylic, recommended to be colored pink
A5G should be cut in 1/4" (5.6mm) acrylic, recommended to be colored green
A5LB should be cut in 1/4" (5.6mm) acrylic, recommended to be light blue
A9 should be cut in 3/8" (9mm) acrylic (or use three copies in 3mm)

A detailed assembly video showing exactly how to put the model together is available at https://mechanicalgifs.com/instructions

Lesson Plan and Activity

Car parts

This model can be used together with the Differential and Rack-and-Pinion Steering models to illustrate how the major mechanical parts of a car work.

Materials Needed

Materials Needed

(1) 1/8" (3mm) clear and optionally colored acrylic.

(1) 1/4" (5.6mm) clear or transparently colored acrylic.

(1) Light-weight, 1/4" (6mm) diameter, 3/4" (20mm) long spring

(1) #6 x 3-1/2" threaded rod (M3 x 89mm)

(1) #6 x 3" round-head machine screw (or metric M3 x 75)

(1) #6 x 1-1/4" round-head machine screw (or metric M3 x 32)

(1) #6 x 1" round-head machine screw (or metric M3 x 25)

(1) #6 x 3/4" round-head machine screw (or metric M3 x 20)

(14) #6 x 1/2" round-head machine screw (or metric M3 x 12)

(26) #6 hex nuts (M3)

(1) #6 lock nuts (M3)

(2) #2 x 1/2 round-head machine screw (or metric M2 x 12)

(2) #2 hex nut (M2)

Two-Speed Transmission from MechanicalGIFs.com