Cardboard Sled
Introduction: Cardboard Sled
My children and I made a cardboard sled to enter in the local races. We decided on a simple bobsled style and whipped up a quick rough plan in Tinkercad. With both limited time and space the main sled was completed in time for the first race. Our design and execution (along with favorable snow conditions) awarded us a tie for fastest time. We decided to make some aesthetic changes before the larger race and added the lighting.
Supplies
1. Cardboard (I mostly used double corrugated cardboard for the structural reinforcements)
2. Adhesives (I used white glue and duct tape)
3. Paint (optional)
4. Crafty Bits (optional)
5. Digispark, WS2812B LED Strip, 5v Power Bank, solder, wire, flux (optional)
Step 1: Reinforce
We started our build with a box large enough for both children to sit in. We glued a large piece of double thick cardboard to the bottom and wrapped it half way up the sides for more durability. I folded up a piece to use as structure and a template for the curve of the nose. This also gave me something sturdy to attach a rope for pulling the sled. We finished off the main body with 4 more ply to sit on, and wrapped the inside and outside of the back with a layer each. The flaps got glued down on the outside.
Step 2: Runners
We glued strips of cardboard with the corrugation channels running vertically. 622
In this configuration the edges can be strengthened with glue. You don't need to fill the cardboard with glue, just get some ~5-6mm into 70% of the channels. This makes the riding edge stronger and on the other side makes a stronger adhesion surface. I had cut out slots in my bottom cardboard layer to glue the runners into.
Step 3: Tape
One layer with small overlap will make it look nice and protect the cardboard. I also added a length using a different color on each runner for the looks and added protection.
Step 4: Decorate
Add paint, glue, and crafty bits to your hearts desire.
Step 5: Make It Glow
At registration for our first race my daughter named the sled Rainbow. With a digispark, a roll of led lights, and a portable power source I decided to make it glow like one. I mashed bits of code I found together to get a rainbow fade effect down the lengths of our sled. I recommend knowing more about programming then I do and writing a better snippet of code. If you are also short on time and learning curve just use what I have attached here. This code uses pin 0 as +5v, pin 1 as data, and pin 2 is neg. This let me plug the factory connector on my LED strip directly to the controllers pins. The length of the sled allowed for 31 LEDs down each side. The digispark was able to drive two strips of 31 LEDs each, wired parallel, without any issues. I am using a small USB power bank to power the lights. The wires, digispark, and battery are hidden in the nose of the sled. 231