This puzzle is designed by Erhan Çubukcuoglu 2012Istanbul /TURKEY

Copyrights Erhan Çubukcuğlu 2012

This document is only for non commercial use. You can make some copy of this puzzle for your own collection, gift, charity organizations

etc..

You can copy, share or publish this document without changing this page and document content.

Contact informationeacubukcu@yahoo.com

For more puzzles my puzzle bloghttp://diypuzzles.wordpress.com/

This document can contain dangerous operations or some mistakes. Everything is your own risk. I am not responsible for any damage.

If you find mistakes in this document please contact me by email that I correct them for you and for other people.

Cargo Boat

Another small and unusual puzzle design from my workshop. This is a small tugboat. I designed this puzzle as a tricky opening matchbox safe. But I don't advise to put matchbox inside of an object attractive for children. This box has not an ingenious mechanism but an easy and funny project.

After this first prototype I made small changes about 3- 5 mm in some dimensions. Your boat will look better. But photos from here may be slightly different from drawings.

HOW TO OPEN THE BOXFor making this box you must understand first “how it works”

This tugboat has two main section

1- The hull2- Tug boat cabinet

First remove the mast at the top of the tugboat. Use this mast for pushing small pin located in the cabinet. This pin fixes cabinet to chimney. Remove the cabinet. Unscrew small screw at the back of the tugboat. Turn box cover and open it

MAKE YOUR OWN TUGBOAT

The drawings at the end of this document are 1:1 scale. You can print and use them as a cutting template for boat pieces. Also you can take dimensions from drawing by measuring. I will give here important dimensions.

Another important explication:For this project I used a special brass nut and screw. I made them from a 3 mm and 6 mm brass rods. This require some special tools. But you don't need to make them.

You can use a standard screw and nut (if you can find use something brass or stainless steel) M3 or equivalent any small screw may be used. You can cut the head of the screw with a small hand saw and use it by fixing into a D6mm x 7mm small wooden piece. And you can mount a standard nut by making a little bigger hole from the back side of the hull middle piece.

I started first by making the body of the box. First cut this 3 pieces

Hull base 105 x 50 x 6 mmHull middle 105 x 50 x 18 mmHull top or tugboat deck (Box cover) 105 x 50 x 6 mm

Make a rectangular hole 60 x 40 mm into the center piece of the hull.

Now this stage is important,

• Fix box cover and box body that you prepared together with a scotch tape or masking tape.• Mark hole centers with a pointed object.• Drill hole in front of the boat 6 mm with a wood drill bit. Depth of hole (15 + 6) 21 mm for

two pieces.• Drill hole at the back of the boat with 3 mm wood drill bit. This hole must be in same

diameter with your screw. Before starting to the project you must find your nut and screw. And calculate the depth of this hole according to your nut.

• Take off the scotch tape and separate two pieces.

The hole on hull center pieces for fixing the nut inside it. You can use a standard small M3 or M4 or equivalent screw and nut

Enlarge the hole on the hull middle according to you nut. If you will use a standard nut, enlarge only from back side. This prevents that the nut comes out. You can fix your nut with a two component epoxy glue.

Glue base pieces to the middle pieces of the hull.

Fix three pieces together with scotch tape, and put inside holes wooden dowels for correct positioning and cut the front shape and back side radius of all three pieces together with a scroll saw.

Cut the front deck with a scroll saw according to drawing template and drill 6 mm hole

And cut the mast from a 6 mm round stock. Length of the mast is about 77 mm

Now we can make the assembly,

• First fix the mast into the body with a carpenter glue,• Mount the box cover,• Fix the front piece to the must in correct position with carpenter glue. Be careful, don't fix

box cover with excess glue.•

Here the result after assembly,

NOTE: In this step the chimney is not made and fixed

Making the tugboat cabinet

You can start by cutting three pieces of wood

30 x 15x 55 mm20 x 15x 35 mmD16 x 48 mm (chimney)

Cut one end of the chimney with a decorative inclination

First drill a 16 mm diameter hole to the top of the bottom pieces. Three side holes are 4 mm through holes.

Now you will close for hole at the back side with four small 4 mm wooden pins and glue. With this method you hide the pin that fix the cabinet to the chimney. All the holes will look same like a boat window.

Two saw trace between windows is for decoration and made with a small hand saw. (See finished boat photo)

Assembly of the chimney

This step is important.

• First fix the cabinet piece to box cover with a scotch tape.• Glue and fix chimney from the hole to correct position.• Drill 4 mm side hole on chimney from the back window.• Remove the scotch tape and cabinet

This method will guarantee to drilling chimney hole to correct position.

Now cut a decorative inclination to top cabinet piece, round corners, make decorative saw traces etc. I describe here basic method and some tips. You can decorate your boat a s you wish.

Drill a D4 mm through hole to the top of the upper cabinet. This is for hiding push stick Fix this pieces with glue to bottom piece.

Cut a D4mm x 30 mm wooden pieces for fixing pin of chimney.

This is push pin at the top of the boat. I made it by drilling the center of a 8 mm rod and fixing a 4 mm rod to the center.

You can use only a 4 mm rod and put a flag on top of it.

Making a mono block piece from wood may be an other alternative

Now your box is finished.

Finish for box:

My favorite way for finish, is oil finish with boiled linseed oil (danish oil teak oil etc may be used). An old school and long way. You can use any method that you like

The easiest way for making this box using drawings as template. Print them without scaling. Cut them from paper and transfer hole centers, cutting lines etc on wood or print drawings on full sheet labels cut and use.

Green lines in drawings are center lines

If you need additional information or if you find a mistake you can contact me by email