makermanuals
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Useless box

Make a box that is absolutely... useless.

Age
9+ yrs
Time
30–45 min

Laser template (useless-box.dxf): scan the QR code

Arm (arm_def.obj): scan the QR code

Laser template Arm PDF
Scan for the online version

What do you need?

Materials

  • 3 mm plywood
  • M3 x 5 screws (3x)
  • M3 nuts (2x)
  • 9v battery clip
  • 9v battery
  • Useless box circuit board
  • Geared motor
  • 3D printed arm
  • Candle wax (optional)
  • Double sided tape

Tools

  • Woodglue
  • Screwdriver
  • Soldering iron
  • Painters tape
  • Wire clippers
  • Wire strippers
  • Lasercutter
  • 3D printer

Steps

Step 1, photo 1
1

Cut the provided template

  • Use the lasercutter to cut the design out of 3 mm plywood
Step 2, photo 1
2

Assamble the box

  • Good to knowYou can use some painters tape to keep the box together while the glue dries.
  • Use some glue to glue the bottom of the box together.
Step 3, photo 1
3

Add the lid

  • Good to knowFor the best result: sand down the edges of the narrow piece marked 'E' with a little file or some sand paper. You can also apply some candle wax to the rounded pieces of the lid.
  • Glue the piece marked E to the box as shown in the photo.
  • Glue one side of the lid
  • Place the lid over the piece marked 'E' and glue the second side of the lid while it is attached to the box.
Step 4, photo 1
4

Solder the cut-off switch

  • Solder the cut-off switch onto the circuit board.
Step 5, photo 1
5

Solder the toggle switch

  • Solder the toggle switch in place.
Step 6, photo 1
6

Attach and connect the motor.

  • Attach the motor with 2 of the M3 bolts and nuts
  • Trim the wires and solder the red wire to the MOTOR +, and black to the MOTOR - pad.
7

Add the battery clip

  • Soilder the battery clip wires to the board. Red goes to 'Battery +', black goes to 'Battery -'
Step 8, photo 1
8

Attach the arm.

  • Good to knowThe hole in the arm has a shape that should match the motor axle. Make sure you pay attention to the shape when attaching.
  • Attach the arm to the motor axle using an M3 screw.
Step 9, photo 1
9

CLose it up

  • Use some double sided tape to place the battery in the box.
  • Push the toggle switch trough the hole in the plywood, with the arm pointing to the narrower side of the wood.
  • Align the shape of the PCB with the slit in the wood. Place the wooden panel on top of the box.
  • Done!