project 0050 sonic crossbow .pdf



Nom original: project_0050_sonic_crossbow.pdfTitre: SonicAuteur: Ritchie

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Rev:08/20/13
Designed by:
Ritchie Kinmont

Project #50 Page 1/29
Sonic Crossbow

Sonic Crossbow
About this project:
The Sonic Crossbow is a lot of fun for kids ages 5 to 95. This little crossbow is fired
by pulling down on the clothespin lever which releases the bowstring. The crossbow
design incorporates two handy bolt clips to store extra bolts below the bow. This
project also includes a target for sharpening your crossbow skills

Cock the
bowstring, load
a crossbow
bolt, take aim,
and let the bolt
fly!

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 2/29
Sonic Crossbow

Rev:08/20/13

What’s it made of?
The Sonic Crossbow frame and bow are made from 1 gallon paint stir sticks, two elastic
hairbands for the bowstring, a shoelace to cover the grip, mini hair clips and mini
popsicle sticks for the bolt clips, and a clothespin for the firing mechanism.
Wood clothespin

Elastic hairband
Shoelace

Adhesive-backed craft
foam sheet

Mini popsicle sticks

1 gallon paint
stir sticks

Mini hair clips
© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 3/29
Sonic Crossbow

Rev:08/20/13

What’s it made of?
The Sonic Crossbow bolts are made from hardwood dowels for the shafts, craft foam
for the fins, and foam ear plugs for the tips.

Hardwood dowel

Craft foam

Foam ear plugs

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 4/29
Sonic Crossbow

Rev:08/20/13

What’s it made of?
The crossbow target is made from a full sheet printer label, a piece of poster board,
and a 1 gallon paint stir stick.

Poster board

Ink jet labels

1 gallon paint stir stick

© 2012 SonicDad Enterprises All rights reserved

Project #50 Page 5/29
Sonic Crossbow

Rev:08/20/13

Project Construction
3.0 HRS

LEVEL 5

$10.00

Check out my way cool Sonic Dad
gauges for project difficulty,
time, and cost. Cost of this
project depends on how many
items you have on hand. If you
purchase all items new, cost will be
higher than the approximate cost
shown.

SHOPPING LIST
Quantity

Item needed

Where to find it

See Figure

8

1 gallon paint stir stick (Home Depot stir stick is recommended, see pg. 29 )

Home Depot, hardware store, paint store

Page 2, 4, 29, A,B

1

1/4” diameter hardwood dowel (approx. 32” required)

Home Depot, discount retail store

Page 3, S, U

1

Wood clothes pin

Wal-Mart, discount retail store

Page 2, D, E

Mini popsicle sticks (see pg. 29 for dimensions)

Wal-Mart, craft store

Page 2, 29, L, V

2

Hair elastic band (approx. 6” diameter X 1/4” wide, X 1/8” thick )

Wal-Mart, discount retail store

Page 2, II, JJ

4

Mini hair clips (small enough to clamp around an 1/4” dowel)

Wal-Mart, craft store

Page 2, CC, DD

1

Flat shoelace (black or the color of your choice, 72” long)

Wal-Mart, discount retail store

Page 2, X, Y

1

Avery full sheet ink-jet printer labels #48165

Wal-Mart, discount retail store, office supply store Page 4, GG, OO

1

Piece of poster board or other thin cardboard 4” x 4”

Wal-Mart, discount retail store

1 pkg

Page 4, UU

1 sheet

Adhesive-backed foam sheet, black or the color of your choice (we recommend Craft store, online store
using only Foamies brand for best adhesion)

Page 2, GG, HH

1 sheet

2mm thick non-adhesive backed craft foam (orange or the color of your choice) Craft store

Page 3, OO, PP

Foam ear plugs (orange or the color of your choice)

Page 3, RR, SS

1 pkg

Wal-Mart (gun or pharmacy section)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 6/29
Sonic Crossbow

Rev:08/20/13

SUPPLIES AND TOOLS NEEDED
Item needed

Where to find it

High temp hot glue gun and glue sticks

Discount retail store, home improvement store, craft store

Scissors

Discount retail store, home improvement store

Wood saw (for cutting paint stir sticks, clothespin, and wood dowel)

Discount retail store, home improvement store

Ball point pen or pencil for marking

Discount retail store

100, 150, and 400 grit sand paper

Discount retail store, home improvement store

12” ruler

Discount retail store, home improvement store

Krylon Cristal Clear satin (or equivalent) spray paint

Discount retail store, home improvement store

X-acto knife with sharp #11 blades

Discount retail store, home improvement store

Step 1

Use template to
mark cut lines

fig. A

Print the cutting templates from pages 23 - 25 on
regular printer paper. Lay the template sheets on
your work surface, then lay the stir stick on top
for marking. Use a pen or pencil to mark the cut
lines on each piece to be cut. Mark and cut the
clothes pin as shown on the template. (fig. A)

Use 100 and 150
grit sand paper to
sand edges smooth

Step 2
Use 100 and then 150 grit sandpaper to sand all
the cut edges smooth. You may also want to
remove the printing on the stir sticks for a
better appearance. Sand the printed surface
with 100 then 150 grit sand paper. (fig. B)

fig. B

Mark center
location lines

Step 3
Cut the width of the bow support piece, then mark
and cut the angles. After sanding smooth, use the
template to mark the center location lines as
shown. (fig. C)
© 2013 SonicDad Enterprises All rights reserved

fig. C

Project #50 Page 7/29
Sonic Crossbow

Rev:08/20/13

Step 4

Cut square
corner on top
clothespin jaw

After cutting and sanding the clothespin,
carefuly remove the top jaw. On a suitable
surface, use an X-acto knife with sharp blade to
cut a square corner on the front side of the
semi-circular feature as shown. This will keep the
bowstring from slipping out of the clothespin
before firing the crossbow. (fig. D)

fig. D

Applying a little glue on
each side of the spring
will keep the clothespin
from coming apart . . .
firing mechanism failure,
bummer! After gluing, the
clothespin may feel a bit
stiff. That’s ok – the
stiffness will help keep
the bowstring in place
before you fire.

Step 5
Use your fingers to spread the clothespin apart
as shown. Apply a small bead of glue on each side
of the spring and let the clothespin relax. Apply
glue in each spring slot to secure the spring to
the clothespin. Wipe away any excess glue. (fig. E)
Spread clothespin
apart

fig. E

When you are finished
cutting and sanding, lay
all the parts out to make
sure you have cut every
piece you will need. Just
compare to this picture
to double check. These
pieces are for the
crossbow, so if you are
also making the target,
you will need the two
pieces from page 26.

`

Apply glue on
each side of
spring
Apply glue in each
slot to secure spring

All pieces required

Step 6
When you have cut and sanded all the pieces
required for this project, lay them out to double
check your pieces and quantities. You should have
all the pieces shown. The pieces shown are for
constructing the crossbow; if you will be building
the target, please refer to sheet 26 for the
pieces required. (fig. F)
© 2013 SonicDad Enterprises All rights reserved

fig. F

Project #50 Page 8/29
Sonic Crossbow

Rev:08/20/13

Step 7
Print the frame assembly template sheet from
page 27 on regular printer paper and lay it on
your work surface. Use high-temp hot glue to
attach all pieces in this project. Using the
template for location, attach the frame center
piece to one of the outer rails as shown. Be sure
to line the pieces up carefully with the template.
(fig. G)

Use template to
attach frame center
to side rail

Take your time when
assembling these first
two pieces. It’s important
to get this alignment
right so the rest of your
crossbow will fit together
nicely. I always like to
test fit the pieces
together before gluing
because you only get one
shot at it! The nice thing
about hot glue is it sets
up fast, the bad thing
about hot glue is it sets
up fast! So be sure you
know how the pieces go
together before you glue.

fig. G

`

Step 8
Attach the inner grip piece in the position
shown. (fig. H)

fig. H

Attach second rail
piece lined up with
the first

Attach inner grip
piece

Step 9
fig. I

Attach the second rail piece as shown. Be sure
to line the edges up with the first rail piece.
(fig. I)
© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 9/29
Sonic Crossbow

Rev:08/20/13

Step 10
Attach the two outer grip pieces in the position
shown. (fig. J)

fig. J

fig. K
Attach two outer
grip pieces

Attach modified
clothespin

Step 11
Attach the modified clothespin in the position
shown. (fig. K)

Attach mini popsicle
stick flush with rail
on each side

These little popsicle
sticks are great at
guiding the bowstring as
it snaps out of the
clothespin. Locating these
little guys is important.
Glue them flush with the
top of the rail and flush
with the half-round
feature in the clothespin
lower jaw. Bowstring
guidance . . . cool!

`

Line up flush with
clothespin opening

fig. L

Step 12
Attach a mini popsicle stick on each side of the
frame to serve as a bowstring guide. Locate the
guides flush with the tops of the rails and flush
with the opening in the clothespin lower jaw as
shown. (fig. L)
© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 10/29
Sonic Crossbow

Rev:08/20/13

Step 13
Sand front and
top smooth

Use a piece of 150, then 400 grit sandpaper to
sand the rails smooth to prevent the fabric
sheath on the bowstring from snagging on the
wood fibers. Sand the top and front angled
surfaces of the rails completely smooth and
rounded as shown. (fig. M)

Attach bow
support

fig. M

Step 14
Attach the bow support to the frame using the
center markings for alignment as shown. As the
glue begins to cool, check the support to be sure
it is perpendicular to the frame. (fig. N)

fig. N

Step 15
Attach each bow to the support and frame in the
positions shown. (fig. O)

fig. P

Attach support
block on each side

Attach each bow to
the support and frame

fig. O

Step 16
Attach a support block on each side of the frame
in the position shown. (fig. P)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 11/29
Sonic Crossbow

Rev:08/20/13

Step 17
Add a bead of glue in the areas shown to
reinforce the bow and frame. Use a paper towel
to wipe away any excess glue. (fig. Q)

Apply glue to reinforce
bow and frame

Attach mini popsicle
stick on each side

fig. Q

Step 18

fig. R

Attach a mini popsicle stick centered below each
side of the bow support as shown. Align the
popsicle sticks parallel to the frame. (fig. R)

Step 19

10”

Mark and cut three 10” long pieces of 1/4” wood
dowel for bolt construction in a later step. Sand
the cut edges with 150 grit sandpaper. Sand the
surface of the dowels smooth using 400 grit
sandpaper. (fig. S)

Sand smooth

fig. S

fig. T
Step 20

To give your Sonic Crossbow a durable finish,
sand all visible surfaces with 150, then 400 grit
sandpaper. Thoroughly clean all surfaces and
apply one coat of Krylon Crystal Clear satin or
equivalent. (fig. T)
© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 12/29
Sonic Crossbow

Rev:08/20/13

Step 21
Lightly sand all surfaces again with 400 grit
sandpaper, and apply a final coat of clear. After
the final coat is dry, sand again with 400 grit until
smooth. Be sure the top and front surfaces of the
rails are smooth. (fig. U)

fig. W

Final sand
smooth

Step 22

fig. U

Step 23
Apply one coat of Krylon Crystal Clear satin or
equivalent on two mini popsicle sticks. Set them
aside for a later step. (fig. W)

Thoroughly clean all surfaces and apply one coat
of Krylon Crystal Clear satin or equivalent on all
three bolt dowels. Lightly sand again with 400
grit sandpaper, and apply a final coat of clear.
After the final coat is dry, sand again with 400
grit until smooth. Set the dowels aside for a later
step. (fig. V)

fig. V
Attach shoelace
end to grip

Step 24
fig. X

Attach the end of a flat 72” long shoelace in the
location shown using high-temp hot glue. (fig. X)
© 2013 SonicDad Enterprises All rights reserved

Rev:08/20/13

Project #50 Page 13/29
Sonic Crossbow

Step 25

Carefully wrap the shoelace around on itself
three times, gluing each wrap to the wrap below.
On the third wrap, bring the lace across as
shown and glue to the grip. (fig. Y)

Wrap around
bottom three
times then onto
grip

Tightly wrap
around grip

fig. Y

fig. Z

Step 26
Tightly wrap the shoe lace around the grip with
each wrap tightly against the previous wrap.
(fig. Z)

Step 27
Continue to tightly wrap until the wrap is even
with the bottom of the frame as shown. Glue
this final wrap to the grip to keep all the wraps
tight. (fig. AA)

Wrap until
even with
bottom of
frame

Wrap three times
then cut and glue
end at back

fig. AA

Step 28
fig. BB

Finish by wrapping around three times, gluing
each wrap to the wrap below. Cut the shoelace
at the back on the third wrap. Glue the loose
end down as shown. (fig. BB)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 14/29
Sonic Crossbow

Rev:08/20/13

Step 29
Clip two mini hair clips onto a bolt dowel as
shown. Hold the clips next to the mini popsicle
stick on the frame. Adjust the position of the
clips until they are positioned at each end of the
popsicle stick as shown. (fig. CC)

Space clips even with
popsicle stick ends

fig. CC

Attach clips to
popsicle stick

fig. DD

Step 30
Apply a bead of glue on each end of the first
popsicle stick. Carefully attach the clips to the
popsicle stick as shown. As the glue cools check
to make sure the dowel is parallel to the frame.
Looking at the side, be sure the dowel is parallel
with the bottom edge of the frame. (fig. DD)

Step 31
Attach two more clips to the other side following
the same steps. (fig. EE)

Attach popsicle stick
across clips

Attach second
set of clips

fig. EE

Step 32
fig. FF

Attach the two popsicle sticks from step 23
across each set of clips as shown. Remove the
bolt dowels and set them aside for a later step.
(fig. FF)
© 2013 SonicDad Enterprises All rights reserved

Rev:08/20/13

Project #50 Page 15/29
Sonic Crossbow

Step 33

Print the cutting application templates from
page 28 on a full sheet printer label. Using a
sharp pair of scissors, roughly cut around the
forend grip template leaving about 1/4” margin.
Peal the backing and apply the cutting template
to the backing side of a piece of adhesivebacked craft foam. Carefully cut out the forend
piece by cutting on the template cut lines as
shown. (fig. GG)

Attach forend
grip pad and fold
over other side

fig. GG

Attach cutting
template and cut
out foam pad

Step 34
Remove the backing on the foam and carefully
locate the forend pad flush against the side rail
in the position shown. Press the edge of the
foam piece down firmly all the way along.
Carefully fold the pad over onto the other side
of the frame. Firmly press the pad down on both
sides of the frame. (fig. HH)

fig. HH

Cut on glue
joint

Step 35
Locate the glue joint on the hairband. Cut the band
in the center of the glue joint as shown. Cut two
hairbands. (fig. LL)

10”

fig. II
Step 36

Tie knots 10”
apart

fig. JJ

Hold the two cut hairbands together and tie a
knot in one end. Carefully tie a second knot 10”
from the first. Be sure to remove any twists in
the hairbands before tying the second knot.
(fig. II)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 16/29
Sonic Crossbow

Rev:08/20/13

Step 37
Install the bowstring into the slots on each end of
the bow with the knots on the front side as shown.
Test the bowstring by pulling the strings back as
shown. The strings should stop stretching in about
the middle of the clothespin. Make adjustments in
the knot positions if necessary. Trim off the extra
bowstring length with scissors. (fig. JJ)

Trim after testing

Test bowstring

fig. KK

To get the best
performance out of your
crossbow, you’ll want to
test your string for the
correct tension. It’s easy,
just pull the string back
until it stops stretching.
For the best results you
want the string to stop
stretching in the middle
of the clothespin. You
may have to adjust the
knot position in the string
to get the right tension,
but you can do it!

Place top
hairband on lower

Step 38
Pull the top hairband back and hold it out of the
way. Carefully apply a small bead of glue in the
center of the lower hairband about 1 1/2” long as
shown. (fig. KK)

Apply glue on lower
hairband

fig. MM

fig. LL

Step 39
Working quickly while the glue is still hot,
carefully place the top hairband on top of the
lower to secure them together. (fig. MM)
© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 17/29
Sonic Crossbow

Rev:08/20/13

Making Crossbow Bolts
Mark fin location
lines

Step 1
Use the layout drawing to mark the fin location
lines on the three crossbow bolt dowels as
shown. (fig. NN)

fig. NN

Cut fins out and
remove label

Step 2
Roughly Cut around the fin templates and peel off
the backing. It’s helpful to remove some of the
tackiness of the label by repeatedly touching the
adhesive with you fingers. This will make it easier
to remove the cutting templates from the foam
after cutting. Apply the label to a non-adhesive
backed foam sheet. Cut out each fin and remove
the label. (fig. OO)

fig. OO

The adhesive on the
label cutting
templates can be
pretty sticky! Getting
the label off of the
foam after cutting
can be a chore! I like
to take some of the
tackiness off of the
label with my fingers
before sticking it to
the foam. That way
pealing the template
off after cutting will
be much easer . . .
way cool!

Step 3
Apply a bead of high-temp hot glue on a fin as
shown. (fig. PP)
© 2013 SonicDad Enterprises All rights reserved

Apply bead
of glue

fig. PP

Project #50 Page 18/29
Sonic Crossbow

Rev:08/20/13

Step 4
Attach fin on location
marking

Working quickly while the glue is still hot, attach
the fin on a fin location line. Be sure the fin is
aligned straight down the axis of the dowel.
(fig. QQ)

Apply glue in center

fig. QQ

Step 5
fig. RR

Apply glue in the center on the back surface of a
foam ear plug as shown. (fig. RR)

Step 6
Working quickly while the glue is still hot, place
the end of the dowel in the center of the glue as
shown. (fig. SS)

Place dowel in center
of glue

Straighten tip as
glue cools

fig. SS

Step 7
While the glue is still hot, turn the bolt over as
shown. Use your finger to gently align the foam
tip straight with the bolt shaft. Rotate the shaft
a few time while straightening the tip. (fig. TT)
© 2013 SonicDad Enterprises All rights reserved

fig. TT

Project #50 Page 19/29
Sonic Crossbow

Rev:08/20/13

Target Construction
Step 1

Apply target decal
to cardboard

Roughly cut around the target decal, peal the
backing and apply to a piece of poster board or
thin cardboard. (fig. UU)

Cut target out

fig. VV

fig. UU
Glue base to
upright

Step 3
Use high-tem hot glue to attach the target to
the support in the location shown. (fig. WW)

Step 2
Use the target cutting template on page 26 to
mark cut locations on a 1 gallon stir stick. Cut
the target support and base; sand edges smooth.
Glue the pieces together as shown. (fig. VV)

Attach target to
support

fig. WW

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 20/29
Sonic Crossbow

Rev:08/20/13

Loading Your Sonic Crossbow

To cock your crossbow,
pull back the string
with two fingers like
this. Use your other
hand to open the
clothespin. Insert the
bowstring into the
clothespin and let it
clamp around it. Gently
release the tension
with your fingers and
your crossbow is
cocked and ready for a
bolt to be loaded. . .
cool!

Now load a bolt with one fin
down inside the grove like
this. Slide the bolt all the
way back against the
clothespin. You are now
cocked and loaded!

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 21/29
Sonic Crossbow

Rev:08/20/13

Firing Your Sonic Crossbow

To fire your cross bow,
first take aim at your
target. Then press down on
the clothespin to release
the bowstring and Bamo!
Your crossbow bolt is
screaming across the sky!

Notice to Airmen:
The Sonic Crossbow is
a lot of fun to use, but
if misused it can also
cause serious injury.
Never point or fire
the crossbow at people
or animals. Always
point the crossbow
away from your face
when loading the bolts.
Always shoot at
inanimate targets, like
the one provided in
this project. Please use
the Sonic Crossbow
safely, and have fun!

© 2013 SonicDad Enterprises All rights reserved

Sonic Crossbow
Frame Layout Drawings (½ scale)
(for reference use)

Side View

Top View

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 22/29
Sonic Crossbow
Rev:08/20/13

Sonic Crossbow
Cutting Templates

(print full scale on printer paper)

Bow Qty. 2
(1 gallon stir stick)

Side Rail Qty. 2
(1 gallon stir stick)

Bow Support Qty. 1
(1 gallon stir stick)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 23/29
Sonic Crossbow
Rev:08/20/13

Sonic Crossbow
Cutting Templates

(print full scale on printer paper)

Firing Mechanism Qty. 1
(wood clothespin)

Inner Grip Qty. 1
(1 gallon stir stick)

Outer Grip Qty. 2
(1 gallon stir stick)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 24/29
Sonic Crossbow
Rev:08/20/13

Sonic Crossbow
Cutting Templates

(print full scale on printer paper)

Project #50 Page 25/29
Sonic Crossbow
Rev:08/20/13

Frame Center Qty. 1
(1 gallon stir stick)

Support Block Qty. 2
(1 gallon stir stick)

© 2013 SonicDad Enterprises All rights reserved

Sonic Crossbow
Cutting Templates

(print full scale on printer paper)

Target base Qty. 1
(1 gallon stir stick)

Target support Qty. 1
(1 gallon stir stick)

© 2012 SonicDad Enterprises All rights reserved

Project #50 Page 26/29
Sonic Crossbow
Rev:08/20/13

Sonic Crossbow
Assembly Templates

(print full scale on printer paper)

Project #50 Page 27/29
Sonic Crossbow
Rev:08/20/13

Fin Location Template

Frame Assembly Template

© 2013 SonicDad Enterprises All rights reserved

Sonic Crossbow
Fin Templates/Forend Grip
Template/Target Decal

(print full scale on full sheet printer label)
Bolt Fin
(orange NON adhesive backed craft foam)

Forend Grip
(black adhesive backed craft foam)

Target Decal
(poster board – see fig. UU)

© 2013 SonicDad Enterprises All rights reserved

Project #50 Page 28/29
Sonic Crossbow
Rev:08/20/13

Sonic Crossbow
Key Components Dimensions

Project #50 Page 29/29
Sonic Crossbow
Rev:08/20/13

Please Note: These dimensional drawings are offered as a reference in
finding a suitable replacement for items not readily available in all countries.
Mini Popsicle Stick Dimensions
2 9/16”
(65 mm)

3/8”
(9.5 mm)

3/32”
(2.4 mm)
One Gallon Paint Stir Stick Dimensions
(as found in Home Depot in the US)
12”
(304.8 mm)

1 1/16”
(27 mm)

1/8”
(3.2 mm)

© 2013 SonicDad Enterprises All rights reserved


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