Well, after being inspired by kalkamel's thread, I decided to try my hand at building a hoverboard.
I should have taken more pics from the beginning, but here goes. I started by creating a custom paper size for my inkjet of 8.5" x 26.9" (the longest it would let me make it) and printing the graphics on thin posterboard/cardstock cut to 8.5"x28". Because of the restriction in length, I had to scale the board down slightly. I then 2 pieces of 1/4" foamcore to the correct dimensions, then 2 more 1/2" shorter and narrower. I then laminated these together with the 2 full-size pieces in the middle, with the 2 smaller pieces on top and bottom to allow me to taper the board. I filled in the taper with Elmer's wood filler, cut the angle for the tailkick, glued it back together, and glued on the graphics. Basic board complete:
For the magnets, I found these tapered plastic bowls at the dollar store for 2/$1.00:
I cut the bottom 1/2" off, and cut a piece of plexiglass to fill in the top:
After some gluing, filling, and sanding. Unfortunately they're a bit larger than they should be (about 6" at the bottom) but it'll work for this build.
I cut the base of the magnets from styrene:
I then built the clamp pieces from styrene and disposable plastic plates. I filled in behind the plastic plate pieces to give the piece strength.
I made the center clamp piece from 2 pieces of 1/8" styrene (glued together) and used a 1/2" countersink bit for the holes:
And here's a dry test-fit on the board:
Still some paint work to do, then I'll tackle the top of the board with the velcro, foot disc thing with the pink fuzzy stuff, etc.
I realize it isn't perfect, but total cost breaks down like such:
2 pieces foamcore $6.00
plastic bowls $1.00
plastic plates $1.00
pink paint $3.89
primer $0.96
plexiglass scrap $0.00
2 tubes wood filler $6.00
clearcoat $3.89
thin posterboard $1.96
spray adhesive $4.96
1/8" styrene scrap $0.00
TOTAL SO FAR $29.66
I should have taken more pics from the beginning, but here goes. I started by creating a custom paper size for my inkjet of 8.5" x 26.9" (the longest it would let me make it) and printing the graphics on thin posterboard/cardstock cut to 8.5"x28". Because of the restriction in length, I had to scale the board down slightly. I then 2 pieces of 1/4" foamcore to the correct dimensions, then 2 more 1/2" shorter and narrower. I then laminated these together with the 2 full-size pieces in the middle, with the 2 smaller pieces on top and bottom to allow me to taper the board. I filled in the taper with Elmer's wood filler, cut the angle for the tailkick, glued it back together, and glued on the graphics. Basic board complete:
For the magnets, I found these tapered plastic bowls at the dollar store for 2/$1.00:
I cut the bottom 1/2" off, and cut a piece of plexiglass to fill in the top:
After some gluing, filling, and sanding. Unfortunately they're a bit larger than they should be (about 6" at the bottom) but it'll work for this build.
I cut the base of the magnets from styrene:
I then built the clamp pieces from styrene and disposable plastic plates. I filled in behind the plastic plate pieces to give the piece strength.
I made the center clamp piece from 2 pieces of 1/8" styrene (glued together) and used a 1/2" countersink bit for the holes:
And here's a dry test-fit on the board:
Still some paint work to do, then I'll tackle the top of the board with the velcro, foot disc thing with the pink fuzzy stuff, etc.
I realize it isn't perfect, but total cost breaks down like such:
2 pieces foamcore $6.00
plastic bowls $1.00
plastic plates $1.00
pink paint $3.89
primer $0.96
plexiglass scrap $0.00
2 tubes wood filler $6.00
clearcoat $3.89
thin posterboard $1.96
spray adhesive $4.96
1/8" styrene scrap $0.00
TOTAL SO FAR $29.66