How to Make a Customizable Cardboard Surfer Automaton

If you're anything like me, you've probably dreamed of crafting your own customizable mechanical desk toy. If you do want to create a cool cardboard creation, then this project is perfect for you! I've crafted a customizable automaton that can incorporate virtually any idea you envision. What makes this project truly captivating is its reliance on simple materials like cardboard, wire, and paper. While I opted to attach a tilting surfboard to mine, you can personalize yours with whatever inspires you.

Materials for the basic automaton:

• A small box (I used 8"x3"x3"

• 10 gauge wire, about twice the length of your box

• 18 gauge wire, about two feet

• A small amount of separate cardboard

• Hot glue

Materials for the surfboard and waves (Optional):

• 18 gauge wire, about 6"

• A piece of cardboard at least 2x5 inches

• Hot glue

• Cardstock paper

• Markers to color the surfboard and waves

Tools:

• Needle nose pliers

• Hot glue gun

• Hobby knife

• Ruler

• Pencil

To begin, mark the rough center on two opposite sides of the box using a ruler and a pencil. Next, carefully create two holes at these marked points using a hobby knife. These holes will allow you to thread the crankshaft through the box later on.

Secondly, straighten the thicker wire completely. Next, shape it into a design with two bumps facing opposite directions, resembling the illustration above. Ensure that the wire is sized to fit comfortably above the box, leaving approximately half an inch of clearance between the bottom of each bump and the cardboard's edge. Remember to include a handle at one end of the wire. Also, ensure there is at least an additional inch or more between each bump and the adjacent box wall they face.

Place the bent wire on top of the box and use a pencil to mark two holes along the centerline of the wire, aligned with the bumps. Next, cut out 1/4-inch holes on the box at these marked points. Then, take four equally sized pieces of separate cardboard and hot glue them above the holes to create slits perpendicular to the wire's direction. Ensure these slits are slightly larger than the diameter of your thinner wire.

The connecting rods are going to be what joins the crankshaft and the thing you would want to move. In order to make them, you need to use some of the separate cardboard to cut a strip with a width slightly less than each bump and a length slightly less than the box's diameter. Cut a length of wire about six inches long and straighten it out, leaving a small hook at one end. Thread this hook through the cardboard, then bend the protruding wire in half, parallel to the cardboard. Add a small U curve to the bend so there is a little bit of space between one side of the bend and the other.

Next, measure out a piece of wire about an inch longer than the piece of cardboard. Place the wire parallel to the cardboard and bend it around the short edges of the cardboard to create a frame that lies on the bottom. Crimp the two folds of this brace tightly with pliers. Repeat this process to make two connecting rods.

Next, open both sides of the box and flip it over so the holes are on the bottom. Take the two connecting rods and thread them through the two slits in the box. Use pliers to make a small bend at the tip of each wire. This will prevent the connecting rods from falling into the box during use.

Turn the box on its side and close one end. Insert the unbent end of the crankshaft (the side without the handle) into the opening. Then, thread the handle end through the other opening and close the final flap. Finally, bend the end of the crankshaft without the handle into a small S shape and cut off excess wire.

If you are only constructing the base of the automaton, you may stop here. Feel free to decorate it as you wish and add any attachments to the connecting rods. However, if you would like to create a surfboard as I did, please keep reading. First, take your 2x5 inch piece of cardboard and cut it into any surfboard shape, ensuring it is not so short that it fits between the connecting rods. Now is the time to color your board any color you would like, or make a cool pattern. Use some of the cardboard to cut fins and hot glue them onto the bottom of the board. Once you have made the board, flip it over and bend a length of thin wire about two inches longer than the surfboard cutout. Create a long U shape with right angles, with a base that spans the center of the surfboard. Make sure that the two legs of the shape are equal in length. Bend these legs to an angle where they are spaced the same distance apart as the distance between the two connecting rods. Finally, attach the wire to the surfboard using a hot glue gun.

Thread each leg of the surfboard through one of the bent loops on the connecting rods. Use the pliers to bend the tip of each leg into a hook shape. These hooks should intertwine with the loops of the connecting rods securely. The surfboard should not fall onto its side when in motion.

Now, let's create the waves to finish our automaton! Take some cardstock and cut out two wave shapes. Use markers to color them however you like. Next, fold the bottom edge of each one of these shapes. Place one wave in the front and the other in the back of your automaton. Secure them in place with hot glue.

Finally, enjoy your exciting new desk toy that moves with the waves! Thank you for reading this Instructable. I look forward to creating more in the future, starting with this small project. If you decided to create this automaton yourself, I would love to see what you made by posting a photo of It in the comments area!