This puzzle is designed by Erhan Çubukcuoglu 2012Istanbul /TURKEY

Copyrights Erhan Çubukcuğlu 2012

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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. The cargo of this boat is a matchbox. 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.

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

1- Ship's chimney2- Side cabinet3- Central station4- Hatch cover

First remove chimney (1) by pulling, after take side cabinet (2) by sliding to side and unscrew central station (3) and take apart hatch cover (4). Turn box cover and open it

MAKE YOUR OWN CARGO BOAT

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. This is something special and it's very difficult to find. For this reason you can use a standard screw and nut (if you can find use something brass or stainless steel)

This is my special screw and nut.

You can use a standard screw (instead of my special nut, left photo) and you can use a standard nut (instead of my special screw)

In all explications the word “screw describe a standard screw and “nut” is standard nut

I started first by making the body of the box.

Bottom view Top view

• First cut a piece of wood 120 x 50 x18 mm• Cut inside with a scroll saw according to drawing template

This is the box cover,• For box cover cut a piece of wood 120 x 50 x 6 mm

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 A and B 6 mm with a wood drill bit. Depth of hole (15 + 6) 21 mm for two pieces.• Drill hole C according to the diameter of your screw (I used a special 4 mm brass screw. For

this reason the hole C is also 6 mm on the photo but you can use any small screw)• Take off the scotch tape and separate two pieces.

I prepared The hole on body pieces for fixing the nut inside it. You can use a standard small M4 or M6 or equivalent screw and nut

For making this,

Turn the back of body pieces and enlarge the hole with a bigger drill bit according to your nut.

The back side of the body. You can see the enlarged hole according to nut diameter.

The nut fixed inside the hole

You can fix the nut inside the hole with a two component epoxy glue.

Now cut the base wood 120 x 50 x 6mm and fix with a carpenter glue to the body piece.

Fix three pieces together with scotch tape, and put inside holes wooden dowels for correct positioning and cut the front shape of all three pieces together wit 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,

The small wooden rod at the back side is not fixed. This is for positioning the box cover to correct position.

Now you can shape and finish your boat body with wood files and sand paper.

Making central station

This piece made of two piece of wood. 20x20x 36mm and 20 x 23x 6 mm

Two saw trace is for decoration and made with a small hand saw.

• Cut a 20x20x36 mm block• Drill back side of the wood from back side center according to your screw (for M4 drill a

hole 3.5 mm etc)• Cut the head of your screw.• Fix the screw inside the wood block by turning and with a two component epoxy glue

IMPORTANTCalculate the length of your screw according to the depth that you fixed the nut. The length of screw may be 10-15 mm outside of the wood and total length may be 20 – 25 mm

After you will drill a small 6 mm hole (depth 4 mm) to the side and fix inside it a small 6 mm wooden rod. (length 8 mm 4 inside + 4 for outside of hole)

Making side station

• Cut a 20x20x24 mm wooden block• Make a small spot D16 x 3 mm to the top side• Drill a 7 mm through hole from the center of this spot• Drill a 6 mm hole to the center of side This hole must be in same level with center station

hole. Mark according the drawings.

Making chimney

Cut a D16 x 20 mm round stock with a decorative inclination on one sideDrill it from center D6 mm x 10 mmCut a wooden round stock D6 mm x 53 mmFix this with carpenter glue to the center of chimney

Making hatch covers

• One of them is fixed and one of them is removable• Cut 34 x 23 x 6 mm wood 2 pcs• Fix one of them with glue according to drawing on box cover• Drill two D4 mm x 4mm hole to the back side of other one• Drill also two D4 mm x 4mm hole to the box cover• Cut two D4 x 7 mm wooden rod• Fix them with carpenter glue to the hatch cover (not box cover)

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