PVC Pipe Multi Toy - Absolutely Simple

My nephew's 5th birthday was fast approaching and I had to think of a gift for him.
A TOY for sure... but what? He likes Swords, Guns, Cars, Cranes, Robots ... and this ... and that ... the list is endless!!
I wish there was something that had  ALL-IN-ONE!!

I spent several days looking/searching for some sort of 'ALL-IN-ONE'.
Not having found anything suitable, I decided to design and build one!
That's how the project began.

Being an Architect, I have worked with PVC pipes for temporary structures, furniture, prototypes etc. They are very easy to work with, to fix and to remove. This seemed to have a lot of potential and looked like the most suited material for this project.

Material Decided! - Now to work out a modular system.
For this, I made a list of 15 to 20 items ... sword, car, crane, tank, guns, etc, ...
Tried to draw them in single lines - 'capturing the character' of each so to say.
Then tried to make them using pipes and fittings.
What turned out was like a Puzzle /or/ Assembly /or/ Lego /or/  Mechano kind of toy ..... 
Several pieces can be assembled or re-assembled into various shapes and forms.
And finally it came out as a 'MULTI-TOY-KIT'.

This Multi-Toy was an instant hit! Kids just got hooked onto it!
All other kids (known, unknown, and descendents of distant cousins) are now waiting for their B'day!!

This is extremely simple to make, 
all you need is the desire, hand tools and a few hours to spare.
So let's get going ….

Step 1: Tools:

Simple hand tools are all that you'll need!

1. Pencil for marking
2. Measuring Tape
3. Mini Hack Saw
4. Fine Grade sandpaper or a File
5. Knife or cutter
6. Hand Drill (Manual drill is OK) and some drill bits
 

Step 2: Materials

1.
SCH-40 PVC Pipe - 1/2 inch  dia - One Pipe 10ft long
The PVC pipe I’m using is White, non-toxic, OD=21mm & ID=15mm
 Most white plumbing PVC pipes are listed as non-toxic
(You can check manufacturer's specs prior to purchase)

2.
PVC Pipe Fittings (for SCH-40 ½" Pipe)
L 90degree elbow = 10 pcs
T Standard Tee      = 10 pcs
+ Cross                   = 2 pcs
Coupler                   = 4 pcs
End-Cap                 = 2 pcs
Total = 10+10+2+4+2 = 28 pieces

3.  PVC pipe Solvent cement - Mine is a 20ml tube

4.  Paper - a strip of about 50mm x 100mm

5.  Cello Tape / Scotch Tape

In case you've never worked with PVC before and would like to have more details,
go through the instructable 'PVC 101'  - a good, crisp compilation.

Step 3: Cleaning Markings on the Pipe:

Safety First!
Work in a well ventilated and well lit area
When cutting/scraping/sanding the pipe safer to use a mask & eye protection

Gently scrape the markings using a knife/cutter or fine grade sandpaper.
I prefer to scrape, I find it is the fastest method ... and the least messy
(You could also use steel wool, scotch-brite and acetone to remove the markings)

Step 4: The Marking Jig:

Using cello tape and the strip of paper, make a paper tube. Roll the strip of paper over the Pipe - not too tight - just loose enough so that it easily slides over the pipe. This becomes your marking Jig. You can now slide the paper tube to the required position and draw a line (on the pipe) along the edge of the paper.
 

Step 5: Cut the Pieces:

Mark 43mm from one end of the pipe. Use the Marking jig (the paper tube you just made) to draw a line all around the pipe. Cut using a Hack Saw (Or a PVC pipe cutting tool). The line drawn all around will help you to keep 'on line' and to make the cut nice and square. Use sandpaper (OR a file, OR a knife) to clean the rough edges.

Continue marking and cutting pieces of pipes.
Sizes and number of pieces are mentioned below:

43mm Long = 14 pieces (Let us call these 'S')
109mm Long = 8 pieces (Let us call these 'M')
241mm Long = 4 pieces (Let us call these 'L')
465mm Long = 1 piece (Let us call this 'XL')
Totally you'll have 14+8+4+1 = 27 pieces
        
After cutting all the pieces you'll be left with about 100mm length of the pipe.
Keep it safe - It'll be used later in case you decide to make the 'wheel-assembly' (Step-10)

The lengths and number of pieces are calculated after trying/designing several assemblies. It is important that you stick to the lengths mentioned here. One length of 10ft Pipe will be fully consumed - Nothing wasted!

Step 6: Ease of Assembling/Dismantling:

 IMPORTANT: 

Make cuts of about 12mm length at both ends of each of the 27pcs.
This makes pushing the pipes into the fittings & removing them easy.

Without these cuts, if you push the pipe tightly into a fitting (even without glue), It'll really be difficult for kids to pull it out. So these cuts are a MUST.

Clean all cuts using fine grade sandpaper or a file.

Step 7: Clean and GO!

Clean and wash:
Wash all the pieces thoroughly (to remove any dust, dirt, particles etc).
I soaked the pieces in mild detergent solution for about 5mins and scrubbed them with a soft old toothbrush, washed them clean, and dried using a paper towel.

Start Off:
Now that you have 27 pieces of pipes and 28 pieces of fittings ....
Your 55 piece Kit is Ready to use.
Some examples are given below to start you off.

Make something even more DYNAMIC:
The next few steps (Step-8 to Step-12) illustrate how to make some interesting add-ons and accessories.
That'll take this kit to a Dynamic Dimension

Step 8: Accessory #1: the Robot Face

To make the Robot Face,  you'll need:

1.   End Cap for 1-1/4 inch SCH-40 PVC pipe
2.   End Cap for 1inch SCH-40 PVC pipe
3.   Some black paper (87mm x 18mm) cut to shape as shown in the picture
4.   A Pin with Glass Bead 
5.   Thermocole Balls - for eyes - approx 10mm dia
6.   Black pipe approx 21mm OD (From an old marker/ electrical conduit etc)

Just follow the attached picture - it is self explanatory.
 
My Robot Head:
I've used 10mm Red LEDs instead of thermocole balls for eyes. 
There is a small LED Flasher circuit and a button cell inside the head.
The antenna on the head is a switch - The eyes blink when switched ON!

Step 9: Accessory #2: the Crane Winch

To make a Crane Winch You'll need:

1.  Coupler for 1/2 inch pipe
2.  Coupler for 1inch pipe
3.  3mm Aluminium (From an old Hanger)
4.  3mm Dia Bolts 10mm long with nuts - two pieces
5.  Wooden / Glass / Plastic Beads with 3mm dia hole 
6.  Some Nylon Thread
7.  A small Hook

With the 1/2" pipe coupler:
Cut 17mm pieces from either end of the 1/2 inch pipe coupler.
Cut off 19mm lengthwise - as shown - to form a 'C'
Drill a 3mm Hole exactly in the center.

With the 1" pipe coupler:
Drill a 4mm hole right through the center
Drill two 3mm holes - on only one side of the pipe
Bend the alu rod to  'Z' shape as shown
Bolt the two 'C' parts as shown - these will work as 'snap-on-clips'
Pass the 'Z' alu rod through the 4mm hole and glue two beads to the rod as shown
This forms your crane winch (File ends of alu rod to make them smooth and safe) 
'Wind' the nylon thread and tie a hook at the free end of the thread

Follow the self explanatory images below.

Once the Winch assembly is ready, you can make a working Tower Crane which can lift and lower loads. This could also be an add-on to the Kid's builder kit

Step 10: Accessory #3 : Wheel Assembly

To make Wheels, You'll need:

1.  60mm Trolley Wheels (4 wheels)
2.  M8 x 45 Half -Thread Alan bolts with nuts (4 nuts and 4 bolts)
3.  Wooden/Nylon Dowel which'll tightly fit into the 1/2" dia pipe (15mm long x 4 pieces)
4.  100mm Length of SCH-40 1/2" PVC Pipe (left over from step 5)

Cut the 100mm piece of pipe (left over from step-5) into 4 equal parts (each of 25mm)

Drill 8mm dia hole, through center of the dowels, this should be done very carefully and precisely, you may have to use a vice to hold the dowel while you drill.

Push the dowel into the pipe. The dowel must be a real tight fit into the pipe. Put a dab of glue before pushing the dowel into the pipe. 
Pass M8 bolt through the wheel, hold the nut using a plier and tighten the bolt all the way through, then loosen it by about half a turn. Rotate the wheel and make sure it runs freely.
Put a drop of CA (super glue) or Loctite (nut lock glue) - to glue the nut in place.

(The nylon trolley wheel I've used has a bore of 8.5mm and it rotates freely over the 8mm bolt - Better to buy trolley wheel first then a suitable bolt)

You could also use Roller Skate Wheels. Buy wheels with bearing, in this case tighten the alan bolt all the way through. (No need to loosen it by half a turn because the bearings will make it rotate freely)

Follow the self explanatory images below. Needless to mention that you want to make 4 wheel assemblies!

Step 11: Full Glory

HERE ARE EXAMPLES OF WHAT ALL YOU CAN DO WHEN THE WHEELS ARE READY

Step 12: The Gift Pack

If you make the entire kit with all the accessories the total tally should be:

28 pieces :  Fittings: Elbow, Tee, Coupler, Cross
27 pieces :  Pipes  S, M, L, and XL
01 piece   :  Robot Face
01 piece   :   Winch - for crane applications
04 pieces :  Wheels
________________________
61 Pieces :  TOTAL

61 piece set!  Very easy to loose a few pieces if they aren't kept in a proper container.

Simplest solution: A large and thick plastic bag (perhaps with a zip-lock). 

But if you want to give this as a gift it can't be 'pieces in a plastic bag' ... it better be a little more stylish.

Here's a suggestion for that ..... You'll need:
1.   2ft long piece of 4"dia PVC pipe (I used a grey PVC pipe - got a scrap piece)
2.   Two end caps for this pipe. 

The entire 61 piece set easily fits in a 4inch dia x 2ft long grey PVC pipe.
One of the end caps can be cemented permanently to the pipe. The other end cap will act as the lid. Grey was looking a bit boring so I quickly compiled some pictures, printed on self adhesive paper and pasted it over the pipe.
I call the Multi-Yoy-Kit : INFINITE CREATIONS.

Pictures of the container are self explanatory.

Hope you have a great time with this project - making it and using it.
Enjoy! 

Raj Quest!