Cardboard and Paper Thumb Spring Toy

Making a cardboard and paper spring thumb toy has been on my list of projects for a while. I have a few wooden ones that I have enjoyed for many years. 

The toy works by pushing up the inner piece in the base to compress the spring - which makes the figure drop down.

when releasing the compression of the spring, the figure returns to the original position.

Therefore, I designed one and away I made. I have to say that working with paper and cardboard for certain parts was a challenge. I made several sample test parts from various materials and using different glues. I also practiced on drilling and sanding these samples. I was not sure of calculating the strength of the spring in relation to the weight and size of the toy. Well, please see the following steps of my process.

Supplies

Cardboard

Solid Cereal box 1 mm thick - cut to size as needed

Corrugated Shipping box 1/8 inch thick - cut to size as needed

Paper

20 pound 8.5 X 11 inch - cut to size as needed

80 pound 8.5 X 11 inch - cut to size as needed

Paint

Acrylic craft pain, various colors

Glue

Wood glue

Super glue - gel

Fast dry paper glue

Modge podge - craft glue

Spring

I used a spring from a power weed wiping machine.

Wire and string

Fine stainless steel wire - .020 inch diameter

fishing line * 8 pound test

Craft water

Used for:

• wetting cardboard
• Thinning wood glue
• Cleaning brushes

Tape - blue easy peel off type

3/4 inch diameters PVC pipe joint connectors

Paint brush

Glue Brush

Paint cup to hold paint

Cup to hold glue

Cooking sheet = tin - to contain spills and drips'

Craft saw - fine tooth for cutting paper

Back saw - coarse saw used to cut cardboard

Small miter box

Paper cutter Optional

Self healing cutting mat

Spring clips

• Small - I used approximately -10X
• Medium 4X
• Sliding clamp small 2X

Scissors

Wire cutters

pliers

Hole punch

Plastic glue block 6X

1/8 inch diameter drill bit and holder

small dremel for drilling

Files and sandpaper

Medium flat file

1/8 inch diameter round file

Med and course board files = aka nail files

220 and 180 sandpaper

Razor knife

1/8 inch diameter brass rod - I used 36 inch length

Plastic ear swaps - cut one end off to use for wrapping

Design items

Steel 12 inch ruler

micrometer

mechanical pencil

fine and med black markers

Circle templates

small angle square

Base or stand

Using 1 mm cardboard - cut three layers

I used the 20 pound paper to wrap and make a template for cardboard

Wet cardboard to ease the bending

Wrap first layer around pvc pipe as shape fixture and hold in place using spring clamp

using wood glue for bonding agent

Wrap second layer after apply glue to the first layer to bond to second layer then do the same for the third layer.

After drying - I waited over night to remove from pvc fixture

Bottom embellishment

I measured the out dimension of the base

cut 1mm cardboard

Marked out a straight line

using hole punch i cut holes along the line.

I marked my punch with a black marker to keep the holes straight

used scissors and cut the middle of the holes

using wood glue and spring clamps attaching it to the base.

Outer and inner caps

I wanted to make sure the top or cap of base will be strong enough and not push out.

So, I designed it to avoid a butt joint. I did one cap to go inside with rolled over edge to be glued inside the base.

the out side cap also had a rolled over edge to glue on the outside of the base.

I needed to cut the the edge to ease the roll over to meet the rounded edge.

Wetting the cardboard helps in the fit.

Using wood glue

the inner cap the edge was glued and push up into place to the top of the base.

I made a special clamp for the outside from a plastic binding strap. Using blue tape made a nice clamp around or 360 degrees of the outer cap.

Make sure to put wood glue on the surface between the inner and outer cap.

The push plate

I used the pvc pipe to draw out 2 round pieces of 1 mm cardboard

Paper glue

spring clamps

Drill two holes thru top caps and push plates

The goal of wrapping is to create an opening for the string to freely pass thru the components.

(i tried drilling the holes and it did not work for me)

I use the drill for cleaning out the holes and drilling the solid components - later.

Using

• 1/8 inch
• brass rod
• plastic swap

Wood glue

I cut approximately 3/4 to 1 inch wide strips of paper

The cardboard I cut oversized to the needs of the different components need

MAKE extra components

Paper wrap components

(might need several wraps to build up to the needed diameter)

first wet the wrap

attach the paper

Apply wood glue on one side of paper

For the paper I wrapped down in a spiral manner

Holding the start and end with either a spring clamp or tape.

Cardboard wrap components

wet the wrap

with the over size widths I do a straight wrap around the 1/8 form.

apply wood glue to one side of the cardboard

roll the carboard on top of itself

My drying rack was to stick the rods in between the wall studs.

Cut to length

marking the dried wraps to the needed dimension

cut the paper with fine saw

cut the cardboard with the coarse saw

smooth the edges with files and sand paper

Make sure the holes are clean and clear so the string can pass thru.

Hands and feet

I stacked the 1 mm card board to build up to the needed dimentsions

I used wood glue and let dry with plastic blocks and small spring clamps

once dried I drilled 1/8 holes for string

shape and clean up edges with file and sand paper

upper and lower body components

I used packing box cardboard - it is lighter and allows to build up to the thickness quicker.

using wood glue and I used just a small slide clamp to hold together for drying.

once dry, I drilled the string holes.

shape and clean up edges with file and sand paper

I had two components spilt apart

I used super glue gel to repair

worked great

Using the fishing line (string)

I used various tools and wires to push the string thru the base

upper body

• I used a looped wire
• put the loop in the arm holes and threaded the string up
• pulled the loop out the arm to draw the string out

lower body

• used a hook wire
• pull the string up thru the leg holes
• to the center body hole

I used spring clamps to hold the spring and push plate in compression

put thru push plate and knot below

I cut three strings a little over 12 inches each. will need extra for knots

1 for each arm

1 to go thru the to the head.

2 strings will run together and split at the upper body

one out the arm

one out the head

spring clamp the three to strings

Test by taking off the compression clamps

push up and let go to test

.

Disassemble the testing of the figure

Using craft paints

colors I choose was random

I put the components on the brass rod to hold while painting

Once I had painted the components I put on a rack to dry

It was hot today, so I put them outside to dry

After the paint was dry

I used various tools and wires to push the string thru the

base

upper body

• I used a looped wire
• put the loop in the arm holes and threaded the string up
• pulled the loop out the arm to draw the string out

lower body

• used a hook wire
• pull the string up thru the leg holes
• to the center body hole

I used spring clamps to hold the spring and push plate in compression

1 for each arm

1 to go thru the to the head.

2 strings will run together and split at the upper body

one out the arm

one out the head

spring clamp the three to strings

Make a knot in each string

I added braided twine in the knot and then used super glue gel to hold

Let glue dry

release compressed spring in base

Enjoy