How to make wooden helicopter?

The design for this toy came from Doug Brown and his Wood-to-Wonderful charity. Helicopters are one of the more unusual vehicles for a toy but kids really like it.

It is provided for your use free of charge. It is not intended for commercial use.

If you are so inclined, a tax deductible donation to our charity would be appreciated. Mail to: Woodworkers for Children, 21 Wild Hunt Court, Laytonsville, MD 20882. 

WOODWORKING EQUIPMENT NEEDED

Band Saw (or scroll saw or coping saw)

Drill Press and 7/32", 15/64", and 25/64" drill bits

Sander

PARTS LIST

body . . . . . . . . . 3 3/4 in. x 2 in. x 3/4 in. walnut

blade. . . . . . . . . 2 7/8 x 3/4 in. x 1/4 in. birch

blad cap . . . . . . . 1 in. x 3/8 in. wheel

blade axle . . . . . . 7/32 in. axle peg

wheels (4) . . . . . . 1 in. dowel cap

axles. . . . . . . . . 3/8 in. dowel

wood glue, sand paper, mineral oil.

INSTRUCTIONS

1.One may use a solid piece of wood as the helicopter body or one may glue up a body with different colored wood to make it more interesting. Here is one example of a multi-colored body.

Glue two pieces of 15/16" x 3/4" walnut and one piece of 1/8" x 3/4" birch together to form wood for body. The birch forms a stripe between the walnut.

2.Trace pattern onto helicopter body.

3.Cut out the body using a band saw. Leave the line!

4.Sand the helicopter body to remove band saw marks using the line as a guide.

5.Use a router with 1/16" round over bit to round edges of body. One may also use sandpaper to round the edges.

6.Use sander to round end of blade and drill a hole in its center using a 15/64" drill bit.

7.Drill the hole in the top of the helicopter for the blade. Use a 7/32" drill bit. It should be deep enough to hold the blade axle.

8.Drill the front and rear axle holes in the body. Use a 13/32" drill bit. The centers of the holes are located 5/16" from the bottom and about 9/16" from the front and back.

9.Assemble the blade axle through the 1" wheel and blade. Glue it in the hole in the top of helicopter body.

10.Cut front and rear axles to length. Assemble axles in axle holes and glue dowel caps to ends of axles.

11.When the glue has dried, ensure all wheels still turn freely and can not be pulled off the body. Check for rough spots and sand if necessary.

12.Apply mineral oil to the wood and let it absorb overnight. Mineral oil is used because it is an eatable oil so there is no harm if a child puts the toy in its mouth. It is available in drug stores.