Pneumatic ArmAssembly Instructions

Contents of Pneumatic Arm Kit

Wooden pieces (⅜” cross-section): 1 X 24”; 1 X 21⅛”; 8 X 7½”; 4 X 7⅛”; 4 X 7”;2 X 4⅞”(each cut into two smaller pieces at an angle); 1 X 3”; 1 X 2¾”; 4 X

2⅜”; 4 X 2”; 2 X 1½”; 3 X 1¼”; 7 X ¾”

Green corner gussets: 6 cardsSyringes, 20cc: 4 (2 have holes in the plunger, 1 of which is trimmed)

Syringes, 10cc: 2 (1 has a hole in the plunger)Plastic Tubing: 1 length approx. 6ft.

Wooden dowel, 3/16” diam.: 2 X 3½”; 1 X 2½”; 3 X 2⅛”; 3 X 1½”; 6 X 1”Wooden dowel, 7/16” diam.: 1

Axle Holders: 18Syringe Holders: 3Rubber bands: 2Mini-washers: 10Stirring Sticks: 2

Objects: 2 x 3”(1 round, 1 square)Platforms: 2 (both drilled, 1 trimmed)

Plus a piece of sandpaper

Kit Contents

Assemble the two “fingers” that make the claw. Two pieces are used for each finger and they are both cut at an angle at one end. The smaller of the two

pieces has two holes. For each finger glue the two pieces together and reinforce them using strips of cardboard cut from the edges of a green corner

gusset sheet.

Using the two longest pieces, one 24” long and the other 21⅛” long with a hole at one end, and 7 short pieces each ¾” long, assemble the arm structure.

Glue a ¾” piece at the “even” end and pieces 2”, 4”, 9” and 16½” from the same end, securing with green gussets.

Glue another ¾” piece ⅛” from the piece closest to the hole as shown below. Lastly glue the remaining ¾”piece next to this last piece.

Use the two elastic bands to hold the arm in position while the glue dries.

Using 4 pieces each 2⅜” long and 8 corner gussets, 4 on each side, assemble a 2¾” square as shown. Allow the glue to dry on each side. Create 4 “double

gussets” and glue these onto the corners of the square.

To assemble the tower structure that will house the arm you need 4 pieces 7” long, 4 pieces 2” long, 3 pieces of dowel 2⅛” long and one 1” long, the

untrimmed square platform and two of the smaller wheels with larger holes. The larger 2½” long, 7/16” diameter dowel is also needed.

The 7” pieces have a hole drilled in their base. To begin assembly, glue the 4 dowels into these holes.

Using the 2” pieces create two forms as shown below, using 8 gusset corners to secure the pieces on each form. The top edge of the 2” cross members are

2” and 5” from the top end.

While these dry glue two small wheels with the 7/16” hole onto the top and bottom of the “untrimmed” platform using the larger dowel as guide. Then glue the dowel into the hole – it will flush with the wheel on the topside.

Once the forms are dry carefully insert the “legs” through the four holes in the platform, as shown. Finish the “tower” structure by “capping” the four ends at the top of the tower with the 2¾” square. The “double” gussets house the four

“loose” ends.

Glue into place two axle holders on each side of the four cross members of the “tower” structure. Use the two 3½” axles to align the set of four axle holders

so that they are perpendicular to the structure and that they turn freely.

Glue 4 grey axle holders so that their holes are 14” from the “even” end of the arm structure. It is useful to mark the axle holder where the centre of the hole is and align this with a measure on the arm. It is important that all the holes

align and that they are perpendicular to the sides - use an axle to check. Similarly glue 4 more axle holders 11” from the “even” end. Place the arm on

one side and allow the glue to dry thoroughly.

To assemble the base, 4 pieces each 7½” long with a hole 2¾” from one end, are joined using 8 corner gussets to form a square. The holes must be aligned

as shown below.

Once the base is dry, 2 pieces, each 7⅛” long are glued into position 3” from the outside edge to form a platform upon which a large wheel will be glued. The base is finished by gluing another 7⅛” piece along one side parallel to

centre pieces. This piece has a hole 3” from one end and must also be aligned as shown.

A second piece, also 7⅛”, is glued next to it. A second square of equal size is also required using four more pieces 7½” long

and 8 corner gussets, 2 at each corner, one on each side.

Glue a large wheel with a ⅜” hole onto the center pieces as shown below.When the second frame is turned upside-down or “flipped 180º” and placed on the first base, the holes in the sides align and may be joined using 1” dowels

as pegs.

Using a smaller wheel with a small hole, trace out its shape onto the back of a corner gusset sheet and cut out the circle. Glue this onto the wheel and when dry, glue the wheel with the cardboard up onto the base so its hole aligns with

the hole in the 7⅛” wooden piece. Glue a 1” dowel into the second smaller wheel with the small hole so that it flushes with one side and then carefully

place this into the other wheel so that it rotates freely. A grey syringe clip is mounted on the smaller wheels towards the back portion of the top wheel.

To make the syringe platform use 3 pieces each 1¼” long. Join them along the long side and cut out two strips of green card and glue them to form a

platform 1¼” X 1⅛”. Glue two grey axle holders as shown making sure that the holes are aligned and perpendicular to the short side. Trim the edges of the

axle holders as shown.

Using a large wheel, trace its shape onto a green card and cut out the circle. Glue this onto the large wheel cutting out the centre hole. Carefully insert the plunger of a 20cc syringe - the one that is not cut – onto one of longer legs.

Make sure the leg the plunger is insert onto is adjacent to the short leg. Carefully place the second “trimmed” platform onto the legs and the 7/16”

dowel.

Glue the larger wheel with the cardboard circle so that it is facing away from the tower. The ⅜” dowel will protrude at least ½”beyond the wheel and the

three smaller dowels ¼” beyond the “trimmed” platform.

Place the tower, with the second “trimmed” platform acting as ballast, onto the base by inserting the 7/16” dowel into the large wheel on the base. Ensure that the tower rotates freely. Carefully insert the plunger into the

barrel of the 20cc syringe and push that barrel into the syringe clip as shown. The lip of the barrel will sit just over the edge of the small wheel.

Firmly place a syringe clip onto the 1¼” X 1⅛” platform and, using a 3½” axle, mount the platform in the middle of the tower using the lower set of axle

holders, then finish with 2 mini-washers. Select the syringe that has the cut plunger and place this syringe into the clip. The cut plunger will be connected

to the arm once the arm is mounted into the tower.

Carefully trim the green gussets that are closest to the uneven end of the arm as shown. Glue the 2¾” piece between the two fingers of the claw and secure

with a strip of green cardboard on the inside. Also glue a 2”strip of green cardboard along the inside of the 24” piece. Glue a 1½” dowel into the hole of the 3” piece that is ¼” from one end. When the claw is dry, use the remaining two 1½” dowels to connect the claw to the arm as shown. No glue is used, the

pieces are secured by the axles and four mini-washers. Check that the claw opens and closes freely.

Firmly place a syringe clip onto the arm where the two ¾” pieces are glued together but not over the ⅛” gap. Select the 10cc syringe with a hole in its

plunger and push the plunger onto the 1½” dowel and the barrel of the 10cc syringe into the syringe holder. The lip of the barrel fits into the ⅛” gap. Finish

with a mini-washer (not shown)

Using a 3½” axle mount the arm into the tower using the set of four axle holders nearest the top. Using the 2½” axle and the cut plunger of the 20cc syringe connected to the syringe platform carefully extend the plunger and connect to the remaining four axle holders on the arm. Finish with two mini-

washers.

Finally use two pieces each 1½” long and glue them onto the arm, 3” apart, at the end without the claw.

The wooden block may be placed between them to act as a counter-weight. Use two 18” lengths of tubing for the 20cc syringes and the remaining length for the 10cc syringes. When connecting these ensure that the plungers are

complementary, i.e. if the arm is at its lowest point the syringe on the syringe platform will be closed so its connecting syringe will be open.

The arm will be capable of picking up an object, rotating and placing it elsewhere: