Toy Scooter - The Woodworkers Institute

8/4/2019 Toy Scooter - The Woodworkers Institute

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Toy scooter

MONDAY 18 JULY 2011

James Hatter's fab toy for kids

1.The completed scooter

The popularity of toy scooters is very evident, with

the abundance of youngsters eagerly fizzing along

pathways. A particular increase is with versions for

children that can be enjoyed by three-year-olds,

although some two-year-olds are getting in on

the act! With parental guidance, these are also auseful learning tool for

balance and coordination. A recent development

has been the lean and steer type, with two wheels

in the front and one at the back. These use a

sprung pivotal system. Alternatively, a scooter with

two wheels at the back and one in front gives a

similar stabilising effect, but are steered in the

normal way.

Safety First

There are important issues that must be addressed when

making toys. These relate to the safe practices and materials

used to ensure they do not pose a risk to the young user. A

clear guidance is found in the European Toy Standards EN71,and these must be adhered to. Essentially, the structure must

not use hazardous materials, or have features that can cause

injury. These standards have been followed in the construction

of the scooters featured in this project. The materials used

include plywood and hardwood, all edges have been rounded,

and finished with a low VOC water-based varnish or paint.

The screws and other fixing items have had PVA adhesive

added to give protection against becoming loose, and wood

plugs used to cover most screw heads. The final nuts used

have a nylon insert to reduce the risk of loosening. The

steering joint has been limited to ensure that it does not

become a finger trap. Having taken all steps to ensure this, it

must be stressed that a toy of this type should only be used

while there is a responsible person present, and a safety

helmet should be worn. The larger wheels used for this project

are 102mm diameter moulded disc type. They have a hub

width of 20mm and a bore of 6.35mm. The rear wheel used in

version two is a 50mm fixed wheel castor. The spindles used

for the moulded wheels are M6 roofing bolts.

Cross dowels are used to secure the front steering columnsupport parts, and to the deck. These provide a very strong

joint. These require a 6mm hole to take the cross dowel screw

and a 10mm hole to take the cross dowel. It is preferable for

the 10mm hole not to be drilled all the way through, for added

strength.

General Information

Moulded Disc wheels used are 102mm, Ref DW102 supplied

by Hobbies Ltd.

Tel: 01508 549333

Website

Adhesive, PVA adhesive, screws, roofing bolts, cross dowels,
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This project looks at two designs:

one with two wheels at the back and one in the

front; the other had two wheels in the front and one

at the back, although both versions had the normal

steering function. Both versions have been tested

and proved to be strong and stable in use, and both

versions are described. Both versions are intended

for three- to four-year-olds.

Step 1

First, cut the deck blank to size using 12mm

plywood. Then cut out the indents that will recess

the rear wheels

Step 2

A table saw can be used to remove the unwanted

pieces, alternatively use a bandsaw or hand saw

Step 3

Cut the front sides of the blank to a taperStep 4

Cut a reinforcing plate using 6mm ply and attach to

the bottom of the deck using screws and adhesive.

Make sure that the threads of the screws have

adhesive on them to reduce the risk of a screw

coming loose

Step 5

The deck can now have the edges painted and

varnish applied. Use safe water-based finishes. Cut

support blocks for the rear wheels, using ahardwood for strength. Then drill 6mm diameter

holes to take the wheel spindles

Step 6

Attach the blocks to the top of the deck using

adhesive and screws

Step 7

Cut the components for the front steering column

support. Use a hardwood for strength and durability

Step 8

Drill the holes for the cross dowel bolts and cross

dowel, plus an additional 6mm hole for a wooden

dowel and one screw hole at the top. Add an

extension piece to the front of the support

Step 9

Drill an 8mm diameter hole through the front of the

support to take the steering spindle. Round over the

front

Step 10

Assemble the front support using adhesive and one

counter bored screw to attach the top piece to the

lower piece

Step 11


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Insert a cross dowel and screw, and tighten firmly

using an Allen key. When assembled, soften all

edges

Step 12

Insert a wood plug to cover the screw head. This

method is used with most other visible screws to

ensure the screws will not loosen

Step 13

Support the front steering upright in a vice or

similar, making sure that it is plumb. Drill a 8mm

hole to a depth of 30mm, for the steering spindle

Step 14

Cut the components for the front steering column.

Cut matching size 20 biscuit slots and additional

screw fitting holes. Drill an 8mm hole centrally in the

small lower support block. This, together with the

hole drilled in the front steering upright, are used to

support the steering spindle

Step 15

Join the components together using the biscuits and

adhesive, and additional screws.

Step 16

Join the final outside components then cover the

screw heads with wood plugs. The completed

assembly can have a clear acrylic varnish applied

Step 17

Cut the handle bar support to size and use a 25mm

Forstner bit to neatly bore the hole. Join to the top

of the front steering upright using adhesive and

screws

Step 18

The steering swivel spindle is 8mm diameter. Use a

plain rod if you have one available. Alternatively,

use a length of 8mm threaded rod and wrap

plumbers' PTFE tape around the threads. This will

give a better tolerance and provide slight lubricating

properties

Step 19

Place the spindle in position with a washer at the

top and bottom of the front of the steering column

support. Engage the spindle in the holes drilled in

the bottom of the steering shaft, and the lower

support block

Step 20

Push the lower support block firmly so that the front

of the steering column support is a snug but free

moving fit. Tighten screws into the block to securein position

Step 21

The wheel is positioned midway in the gap. Use an


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M6 x 100mm roofing bolt that uses nuts and

washers to centralise and secure. Use a final nylon

insert nut

Step 22

Attach the bottom of the front steering support

column using adhesive and the cross dowel fixings.

In addition, a 6mm wood dowel is positioned

between the cross dowel fixings

Step 23

The rear wheels use M6 roofing bolts as spindles.

PTFE tape is again used

Step 24

Feed the remainder of each bolt through the blocks

Step 25

Secure each wheel spindle in position, ensuring that

the wheel can be rotated with minimal friction. Use a

nylon insert nut and

a touch of adhesive to lock the wheel spindle in

position

Step 26

Attach a wheel shield strip into position

Step 27

Feed a length of 25mm dowel through the hole

bored at the top of the front steering upright, and

secure with a screw and adhesive. The scooter is

now complete

Construction differences for scooter with two front wheels

For the scooter with two front wheels, the deck is narrower and a slot is cut

at the rear to take a single wheel.

The wheel chosen was a 50mm fixed castor. Alternatively, a larger wheel

could be used and mounted through the slot, with support blocks either

side.

Cut and attach a reinforcing plate to the bottom of the deck as with the

other scooter, but making allowances for the single wheel.

The castor is fitted on with angled spacers which are glued, screwed and

finally bolted in place, before a thin wood cover is added.

The angled spacers allow the wheel to be raised so that the deck is about

35mm above ground level.

Attach a wheel on each of the front steering column legs using M6 roofingbolts, washers and a nylon insert nut.

Attach the steering column support to the deck using cross dowel fixings

and adhesive. And there we have the alternative build.

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Toy Scooter - The Woodworkers Institute

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Transcript of Toy Scooter - The Woodworkers Institute