Final presentation from one of my student teams in my Design for Six Sigma class at RPI. Excellant application of DFSS to the design of a mouse trap powered vehicle.

1. “Trapped With A Kupholder”
The Greatest Mousetrap Car Yet!
Ayoob Ahmed
Osvaldo Colon-Sandoval
Amanda Learned
December 14th, 2010
DSES-6960 H13 Design for Six Sigma
Instructor: Bob Shemenski

2. Agenda
 Background of our vehicle concept
 Why customers want this kit
 Using CDOV process to enhance the car
 Packaging & Assembly
 Critical Parameters
 Accuracy & Precision of the vehicle
 Ease of use & Enjoying the beverage…

3. Background:
The Team
 Ayoob Ahmed
– Electrical Engineer in Non-Destructive Testing
– Hoping to become a Lean/6 Black Belt to enhance test rig design & manufacturing
– Loves optimizing for a challenge, especially one consisting of drink deliveries!
 Amanda Learned
– Mechanical Engineer in Aero/Thermo Part Durability
– Learning to apply DFSS concepts for proactive durability KPC monitoring in her
route to hold a Lean/6 Black Belt title
– As a true P&W Engineer, loves to see a gear added into the mix!
 Osvaldo Colon-Sandoval
– Project Engineer in F119 Program - Exhaust System CIPT
– Becoming a Lean/6 Black Belt to finally develop a logical & achievable
scope, schedule, & cost for the company‟s most important engine program
– Just happens to have an inner love for mousetrap powered vehicles!

4. Background:
The Mission
 A frequent customer of DocFizzix tapped us on the shoulder, due to
our love for mousetrap vehicles, optimization of drink delivery, and
passion for creative solutions
 With the challenge in hand, our team spent countless* hours to
develop just the right new kit to be marketed through the company‟s
website, hobby stores, & educational product distributors
 Our sponsor desires to grow their market and is looking for a new
product which customers, including students, teachers &
hobbyists, can buy, build and use to compete in a new competition:
“The Milk Run Challenge”
* Actually not countless, please see actual schedule in the back-up slides

5. Customers:
Why This New Kit Will Sell
They talked… Simple mechanics
We listened… - No strings/tangles
- A gear drive
No more than a
and followed through! - A screw-on break
- Simple tools for build
day to build, Interchangeable parts
maybe even Something fairly
- Customizable body
just a few hours simple to put
- Multiple wheel choices
together, but at the use only simple
- Repairable
same time somewhat mechanics in
Easy to use
open ended. design… yet make
- Breaking independent of
it technically drivetrain
I‟d like to challenge my interesting.. but - Reliable for multiple uses
technical skills… must doable in a day… - Safe to operate
be more than just put a
Design “Built to win!”
couple blocks together.
- Delivers large beverages
- Consistent & quick
- Abides by ground rules

6. CDOV:
The Better Way to Design
 Since we are Black Belts in training, the first step taken to develop the new
kit was to decide on a process to follow:
– Concept: linking our product to the market
– Design: translating the VOX into creative prototypes
– Optimize: Concentrating the design to meet design goals
– Verify: Ensuring our product is buildable, reliable, & marketable
 Our product has the customer in mind, with critical features optimized
& verified in order for them to win “The Milk Run Challenge”
 Our team strongly believes that keeping the definition of our
„Customer‟ open from the start and following the CDOV process with
this base, has really helped us to create an innovative product that
will be marketable, even amongst the many other Doc Fizzix
mousetrap powered vehicle options

7. CDOV:
How it Enhanced “Trapped With a Kupholder”
 During the concept & design phases we generated some great creative ideas
to meet the customer‟s need; however, we kept a back-up concept just in
case the lead design was overcome by new failure modes; repetitive testing
was done to ensure “the gear” would be user-friendly & reliable
 At times, there may have been some “heated discussions” in regards to „what
next?‟ OK, to verify, we need a GR&R with 3
users, 3 cars, and total distance
No, we need the 3 cars, breaking, & wheels…
… But “CDOV” pulled us together and kept us moving forward, which
reduced R&D costs associated in the new kit & let us meet customer needs &
desires
Pull up our Critical
Parameters to refer to, to
answer this one!

8. Project Plan:
Actual hours spent on the project…
Schedule Analysis for “Trapped With a Kupholder”
Phase Schedule Actuals Variance
Concept 36.5 31 5.5
Design 27 37 -10
Optimize 37 50 -13
Verify 47.5 46 1.5
180
Totals 148 164 -16
160
140
200 120
100
150 80
60
100
40
50 20
0
0
Concept Design Optimize Verify Totals
Concept Design Optimize Verify
CUM Schedule CUM Actuals
Schedule Actuals

9. Packaging & Assembly:
Getting Started
Items in your package Standard
TWAK
 57 individual pieces Kit
contains
57
individual
 A Manual for assembly & operation Pieces
 Delivered in a priority mail small flat-rate
shipping container
Tools required for assembly
 Wood glue & Super glue
 2 adjustable clamps
 Pliers
 Wire cutters
 A 5/8” drill bit
 Ruler

10. Packaging & Assembly:
BOM, Part and “TWAK” Kit Cost
Sale Price per kit @ $14.89 with a Profit Margin of 30%
Description Size Location Qty Cost Total Cost
Platform 3"x12"x.25" www.hobbylinc.com 1 $ 0.76 $ 0.76
Siderail 1.25"x12"x.25" www.hobbylinc.com 2 $ 0.65 $ 1.30
Front/Rear Axles 0.25" Brass www.hobbylinc.com 2 $ 0.39 $ 0.78
Metal Washers 4 x0.25"ID www.appliancepartspros.com 4 $ 0.10 $ 0.40
Chasis Plastic Washers 12x0.25"ID www.grainger.com 22 $ 0.04 $ 0.88
Mouse trap standard www.acehardware.com 1 $ 0.60 $ 0.60
Axle Gear Plastic www.SmallParts.com 1 $ 0.80 $ 0.80
Main Drivetrain Plastic www.SmallParts.com 1 $ 1.30 $ 1.30
Main Gear Brackets Plastic www.SmallParts.com 2 $ 0.25 $ 0.50
Drive Shaft 0.25"x 3" Brass www.hobbylinc.com 1 $ 0.39 $ 0.39
Drivetrain Gear Support Balsa 0.25" Square www.hobbylinc.com 1 $ 0.10 $ 0.10
Threaded Rod 1.25" of 8-32 Threaded Rod www.hardwareandtools.com 1 $ 0.05 $ 0.05
Wing nut 8-32 Wing Nut www.grainger.com 1 $ 0.40 $ 0.40
Balsa wood .125" x0.5"x3" www.hobbylinc.com 1 $ 0.10 $ 0.10
Braking System Balsa Rod 0.25" Rod www.hobbylinc.com 1 $ 0.02 $ 0.02
Cd's 6 Standard CD's www.meritline.com 6 $ 0.12 $ 0.72
Empty Roll of tape www.rhinomart.com 1 $ 0.87 $ 0.87
Rubber Gromet 0.25" to CD ID www.docfizzix.com 4 $ 0.30 $ 1.20
Wheels & Cupholders Balloons Assorted 6 www.amazon.com 4 $ 0.07 $ 0.28
Totals 57 $ 11.45
Sales Price per kit @ a Profit Margin of 30% $ 14.89

11. Packaging & Assembly:
Simple Steps for a Fun Project
 This kit comes with clear, illustrated, step-by-step
instructions for assembly and operation
– Getting Started (1-3)
– Building the frame (4-14)
– Assembling the large gear (15-22)
– Modifying the Mousetrap (23-29)
– Fabricating the chassis (30-35)
– Making Customizations (36)
– Adding Wheels & a Cup Holder (37-46)
– Affixing the break (47-52)
– Using the Vehicle

12. Packaging & Assembly:
The Final Product
 Drawing with critical features & dimensions
– All critical features, like plastic gears and mouse trap, will be
provided to the customer as part of the package.
– Key assembly dimensions (drawing) will be provided to the
customer on the assembly instructions to ensure proper
performance of the car.

13. Critical Parameters:
Design Score Card
Design score card documenting minimum of 3 system level Critical Parameters
Critical Parameters Units LSL Target USL Mean Std Dev Cp Cpk
Stop Distance (+/- 1 ft of desired distance) in -12 0 12 -0.61 2.13 1.87 1.78
Ultimate Distance (Able to move car min 16 ft.) ft 16 20 24 17.89 0.49 2.73 1.29
Straight Drive "Alignment" (+/- 1 ft after 16 ft.) in -12 0 12 2.97 5.79 1.18 0.97
Able to move 2 gal to dist of 16 ft in less than 30 min min 0 15 30 14.81 5.36 1.11 1.09
ˆ USL LSL
Cp ˆ Min USL x , x LSL
C pk
6ˆ 3ˆ 3ˆ

14. Critical Parameters:
Capability Growth Index (CGI)
• A CGI completed to account for overall subsystems
(braking, stop, distance, time) and target Cp = 2
• Cpi = min(Cp, 2)
n
100 C p i
CGI (%)
i 1 n 2
CGI (%) = 100/4*((1.87/2)+(2/2)+(1.18/2)+(1.11/2))
CGI (%) = 77.0%

15. Accuracy & Precision:
Design Validation
 Cpk‟s for the highest priority critical
parameters, etc…
– Optimized weight capability was set at… 32oz.
 Distance traveled > 16ft… 18 ft.
 Braking capability ± 12” … ± 2” from target.
 Alignment capability ± 12”… ± 4” from axis.
 Competition Time < 30min… 15 minutes.

16. Accuracy & Precision:
Validation of All Design Requirements
Process Capability of Distance Traveled
(using 95.0% confidence) Distance:
LSL USL
P rocess Data Within
LS L 16 Ov erall Cpk of 1.29
Target *
USL 24
S ample M ean 17.8906
P otential (Within) C apability
Cp 2.73
Cp of 2.73
S ample N 16 Low er C L 1.77
S tDev (Within) 0.487589 U pper C L 3.70
S tDev (O v erall) 0.598392 C PL 1.29
C PU 4.18 Overall Performance:
C pk 1.29
Low er C L 0.80 0.08% total population to
U pper C L 1.78
O v erall C apability be out of Limits
Pp 2.23
Low er CL 1.44
U pper CL 3.02
PPL 1.05
PPU 3.40
16.25 17.50 18.75 20.00 21.25 22.50 23.75 P pk 1.05
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.64
% < LS L 0.00 % < LS L 0.01 % < LS L 0.08 U pper CL 1.46
% > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm *
% Total 0.00 % Total 0.01 % Total 0.08 Low er CL *

17. Accuracy & Precision:
Validation of All Design Requirements
Process Capability of Stop Distance
(using 95.0% confidence)
LSL USL
Stopping :
P rocess Data Within
LS L -12 Ov erall
Target
USL
*
12 P otential (Within) C apability
Cpk of 1.78
Cp 1.87
S ample M ean -0.611111
S ample N 18 Low er C L 1.25 Cp of 1.87
S tDev (Within) 2.13809 U pper C L 2.49
S tDev (O v erall) 3.07052 C PL 1.78
C PU 1.97
C pk 1.78
Low er C L 1.16
Overall Performance:
U pper C L 2.39 0.01% total population to
O v erall C apability
Pp 1.30 be out of Limits
Low er CL 0.87
U pper CL 1.74
PPL 1.24
PPU 1.37
-12 -8 -4 0 4 8 12 P pk 1.24
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.79
% < LS L 0.00 % < LS L 0.00 % < LS L 0.01 U pper CL 1.68
% > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm *
% Total 0.00 % Total 0.00 % Total 0.01 Low er CL *

18. Accuracy & Precision:
Validation of All Design Requirements
Process Capability of Alignment
P rocess D ata
LSL USL
Within
ALIGNMENT:
LS L -12 Ov erall
Target *
USL
S ample M ean
12
2.13889
P otential (Within) C apability
Cp 1.18
CPK of 0.97
C P L 1.39
S ample N
S tDev (Within)
18
3.38965 C P U 0.97 CP of 1.18
S tDev (O v erall) 3.35106 C pk 0.97
O v erall C apability
Pp 1.19
PPL 1.41
Overall Performance:
PPU 0.98
P pk 0.98 0.16% total population to
C pm *
be out of Limits
-12 -8 -4 0 4 8 12
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
% < LS L 0.00 % < LS L 0.00 % < LS L 0.00
% > U S L 0.00 % > U S L 0.18 % > U S L 0.16
% Total 0.00 % Total 0.18 % Total 0.16

19. Accuracy & Precision:
Validation of All Design Requirements
Process Capability of Time_Total
(using 95.0% confidence) Time:
LSL USL
P rocess D ata Within
LS L 0 Ov erall CPK of 1.09
Target *
USL 30
S ample M ean 15.3467
P otential (Within) C apability
Cp 1.11
CP of 1.11
S ample N 20 Low er C L 0.76
S tDev (Within) 4.49173 U pper C L 1.46
S tDev (O v erall) 5.24807 C PL 1.14
C PU 1.09 Overall Performance:
C pk 1.09
Low er C L 0.71 0.43% total population to
U pper C L 1.46
O v erall C apability be out of Limits
Pp 0.95
Low er CL 0.65
U pper CL 1.25
PPL 0.97
PPU 0.93
0 5 10 15 20 25 30 P pk 0.93
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.60
% < LS L 0.00 % < LS L 0.03 % < LS L 0.17 U pper CL 1.26
% > U S L 0.00 % > U S L 0.06 % > U S L 0.26 C pm *
% Total 0.00 % Total 0.09 % Total 0.43 Low er CL *

20. Ease of Use:
Operation & Delivery
 In-person demo to be performed.

21. Ease of Use:
Customization
 Deliver the beverage of your choice
– Cup-holder fits all standard sizes
– Steady enough to drive even with a Double Big Gulp!
– Easily swap out cup-holder for “small glasses”
 Wheels easily swap out
– Add balloon-wrap
Bushing simply
– Add rubber band wrap pops off of axel &
– Double-up the CD‟s out of CD center
 Frame can be customized
– Paint it with markers, crayons, pens, or paint
– Add your logo!
– Lengthen or shorten or make cut-outs in frame as desired

22. Ease of Use:
Enjoying the Beverages
For just $14.89 + $4.95 S&H you too could be winning
“The Milk Run Challenge”
 Wow your friends & party guests!
 Draw a crowd into your business $$
 Let students have fun & learn at the same time
…Then you can relax and enjoy the beverages too!

23. Back-Up Slides
GOOD
BAD
UGLY

24. Phase 4 Requirements
Action from Optimize Phase
 Updated design score card including Transfer Functions, predicted Capabilities and
Capability Growth Index (CGI) for minimum of 3 system level Critical Parameters
Verify
 Drawing with critical features and dimensions
 Satisfaction of VOC, both customer and stakeholder needs
 Validation of all design requirements generated in Concept phase
 BOM and parts cost
 Description of assembly, tools and process
 Demonstrate operating procedure
 Design Validation – Cpk for highest priority critical parameters
 Updated Design score card Critical Parameters, Capability Growth Index (CGI)
 Specific details: How DFSS tools and CDOV process influenced the development of
your product design
 Project Plan (actual hours spent on Concept, Design, Optimize and Verify phases)
 Three working prototypes, materials and instructions for in-class competition.
 Verify phase gate scorecard

25. Verify Phase Scorecard

26. A Missing Anecdote from the
Optimize Phase Report:
 The Original Cup Holder was to carry 2 beverage containers, on either side of chassis
 Market research was completed to determine standard cup holder sizes & requirements:
4.25” & 3.75” diameter should fit most all cups (except “Nalgene” bottle type)
 As the design evolved, we were able to optimize the design by carrying more beverage
in a single cup holder, in the center of the chassis
 Testing & analysis showed small cups needed no further support than what the 4.75”
standard cup-holder delivered: stability was consistent with repetitive testing
 A cylinder provides simpler assembly than a 4- or 3-sided design, which requires
multiple pieces and more locations for failure (FMEA)
Design 1: Design 2a: Design 2b:

27. Packaging & Assembly:
The Final Product
 Drawing with critical features & dimensions

28. Packaging & Assembly:
The Final Product
 Drawing with critical features & dimensions

29. Accuracy & Precision:
Validation of All Design Requirements
Process Capability Sixpack of Distance Traveled
I Chart Capability Histogram
LSL USL
UCL=19.353
19 S pecifications
Individual Value
LS L 16
_
18 X=17.891 U S L 24
17
LCL=16.428
1 3 5 7 9 11 13 15 16.25 17.50 18.75 20.00 21.25 22.50 23.75
Moving Range Chart Normal Prob Plot
2 A D: 0.855, P : 0.021
UCL=1.797
Moving Range
1
__
MR=0.55
0 LCL=0
1 3 5 7 9 11 13 15 16 18 20
Last 16 Observations Capability Plot
19 Within Within O v erall
S tDev 0.487589 S tDev 0.598392
Values
18 Cp 2.73 Pp 2.23
O v erall
C pk 1.29 P pk 1.05
17 C pm *
S pecs
5 10 15
Observation

30. Accuracy & Precision:
Validation of All Design Requirements
Process Capability Sixpack of Alignment_1_1
Xbar Chart Capability Histogram
LSL USL
UCL=9.19
S pecifications
Sample Mean
6
_
_
LS L -12
X=2.14 U S L 12
0
LCL=-4.91
-6
1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12
R Chart Normal Prob Plot
UCL=12.25
A D: 0.328, P : 0.489
Sample Range
10
5 _
R=3.75
0 LCL=0
1 2 3 4 5 6 7 8 9 -10 0 10
Last 9 Subgroups Capability Plot
Within Within O v erall
5 S tDev 3.32484 S tDev 3.35106
Values
Cp 1.2 Pp 1.19
0 O v erall
C pk 0.99 P pk 0.98
C pm *
-5 S pecs
2 4 6 8
Sample

31. Accuracy & Precision:
Validation of All Design Requirements
Process Capability Sixpack of Stop Distance
Xbar Chart Capability Histogram
1
5 LSL USL
UCL=4.35
S pecifications
Sample Mean
_
LS L -12
0 _
X=-0.61 U S L 12
-5
LCL=-5.57
1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12
R Chart Normal Prob Plot
UCL=8.613
A D: 0.781, P : 0.034
8
Sample Range
4 _
R=2.636
0 LCL=0
1 2 3 4 5 6 7 8 9 -10 0 10
Last 9 Subgroups Capability Plot
Within Within O v erall
5 S tDev 2.33692 S tDev 3.07052
Values
Cp 1.71 Pp 1.3
O v erall
0 C pk 1.62 P pk 1.24
C pm *
-5 S pecs
2 4 6 8
Sample

32. Accuracy & Precision:
Validation of All Design Requirements
Process Capability Sixpack of Time_Total
I Chart Capability Histogram
LSL USL
30 UCL=30.90
S pecifications
Individual Value
LS L 0
_
15 X=14.81 U S L 30
0 LCL=-1.27
1 3 5 7 9 11 13 15 17 19 0 5 10 15 20 25 30
Moving Range Chart Normal Prob Plot
20 UCL=19.76
A D: 0.179, P : 0.905
Moving Range
10
__
MR=6.05
0 LCL=0
1 3 5 7 9 11 13 15 17 19 0 10 20 30
Last 20 Observations Capability Plot
Within Within O v erall
20 S tD ev 5.3627 S tDev 6.03241
Values
Cp 0.93 Pp 0.83
O v erall
10 C pk 0.92 P pk 0.82
C pm *
0 S pecs
5 10 15 20
Observation

33. “Trapped With A Kupholder”
Build Instructions
Parts, Assembly, & Usage Manual for your
new mousetrap powered vehicle*
*Proprietary
information of
Ayoob Ahmed,
Osvaldo Colon-
Sandoval &
Amanda Learned

34. What is Standard
TWAK
Kit
included in contains
57
individual
your kit Pieces
2 chassis side rails (balsa wood sheet)
2 chassis spacers (balsa wood blocks) 1 large gear with spokes (plastic)
1 chassis platform (balsa wood sheet) 1 small gear (plastic)
4 reinforcing blocks (balsa wood rectangles) 1 bent metal tube
1 break arm (thin wood piece) 2 wheel axels (long metal tubes)
1 round wooden rod 1 gear axel (short square metal rod)
4 standard CDs 1 threaded rod (round metal)
2 balloons (std 8”, optional for assembly) 2 gear mounting feet (plastic)
1 cardboard flattened roll (packing tape 20 spacers (plastic disks)
size) 4 bushings (rubber)
1 mousetrap (standard “Victoria” brand) 4 washers (optional for assembly)
1 wing nut

35. Assembly steps 1-3: Getting Started
1. Lay out the entire contents of your kit
2. Check that all of the parts listed in the “What is Included in
Your Kit” section are accounted for
 If any parts are missing, please visit our website and submit a
communication; please include your kit bar code and the name of
the specific missing kit piece(s)
3. Gather the required equipment needed for assembly, not
included in your kit:
a. Wood glue
b. 2 adjustable clamps
c. Pliers
d. Wire cutters
e. A 5/8” drill bit
f. Ruler
g. Super glue
h. Cup of your choice to carry liquid

36. Steps 4-14: Building the Frame
4. Insert a wheel axel through one hole 9. Slide one end of the 2nd wheel axel
of each chassis side rail through the hole at the other end of
5. Stand the side rails on their edges, as a chassis side rail
shown and align short ends with a 10. When the inserted end is in the
secure straight edge or T-square middle of the 2 side rails, slide the
6. Place a chassis spacer between the small gear onto this end of the axel
two bars, up against the straight edge 11. Continue pushing axel through the
and ensure it is not touching the axel last chassis side rail pre-drilled hole
7. Glue the chassis spacer ends to the 12. Push the small gear towards the
inner side of each chassis side middle of the assembly, until the
rail, with the wood glue back axel looks similar to that shown
8. Secure a clamp on the outer edges of in the picture
the chassis side rails, aligned with the 13. Follow steps 5. through 8. again, for
glued intersections this end of the assembly
14. Set Frame aside to let the wood glue
5. 12 dry
.
8.
14
.

37. Steps 15-22: Assembling the Large
Gear
15. Slide the gear axel through a gear 19. Inject glue in-between the gear
mounting foot, then 3spacer, then the axel and the hole of the mounting
center hole of the large gear, then 2 foot, on both sides of the assembly
more spacers, and finally the 2nd gear
mounting foot, as shown in the
15 picture. This is the large gear
. assembly.
20. Glue a reinforcing block adjacent to
each flat outer edge of the
mounting foot, such that the long
side of each block aligns along the
long edge of the chassis platform
16. Align the large gear assembly in the upper surface, as shown; ensure
middle of the rectangular hole of the the inner edge of each block is
chassis platform flush with the edge of the mounting
foot 19
17. Place the foot adjacent to the outer
“nub” of the gear‟s center hole, on the 21. Repeat step 18. to .secure the
wide surface of the platform; and other mounting foot
place the opposite foot on the thinner
surface of the platform, as shown
16
18. With the large gear assembly aligned
.
17 centered in the platform‟s cutout,
&
.
glue the flat surface of each mounting 22. Set chassis platform assembly
foot to the surface of the chassis aside to let the wood glue dry
platform

38. Steps 23-29: Modifying the
Mousetrap
23. Using pliers, remove the mousetrap‟s 26. Place the mousetrap on the
locking bar top of the chassis
24. Using wire Cutters, cut the platform, adjacent to the
lever/snapper arm of the standard mounting foot for the large
mousetrap at the location marked in gear, on the wider side of
green on the mousetrap the platform, as shown;
supplied, approximately ½ across the ensure the lever arm is
horizontal portion pointing to the shorter end
of the chasses
25. Using pliers, bend the remaining arm
23 length ~90-degrees, toward the
. outside, as shown 27. Align the center of the
25
spring on the
.
mousetrap, with the center
of rotation for the large
gear; as such, the bent arm
24
length should now be
. almost (but just shy of)
touching the gear‟s surface;
mark the front & back of the
mousetrap
28. Once the location is
defined, glue the bottom of
the mousetrap to the top of
the chassis platform;
remember to use plenty of
glue!
29. Insert the bent metal tube

39. Steps 30-35: Fabricating the Chassis
30. Once the glue on the frame and 33. Place glue on the outer edges of
large gear assembly on the chassis the chassis platform then re-align
platform are dry, place the assembly in-between the side rails, using
platform between the 2 chasses side the marks from step 32; slight
rails; ensure the large gear and small forward/aft shifts may be made to
gear are at the same ends of the ensure a good
chasses 34. Secure a clamp on the outer
31. Shift the platform forward and aft, edges of the chassis side
until the teeth of the two gears meet; rails, towards the front of the
the small gear may have to be shifted platform & then secure a second
along the wheel axel clamp towards the rear
32. Once the assembly is placed such 35. Set chassis assembly aside to let
that the teeth of the two gears 33 the wood glue dry
intersect and are able to rotate and .
31 catch on each other, mark the
. location of the front & back edges of
the chassis platform on the side rails;
4 marks should be made it total
32
.
35
.

40. Step 36: Making Customizations
 Balloons are provided, if it is  Washers are provided, these may
desirable to have additional friction be used to reduce friction between
on your wheels – and if you want to your axel and the chassis
add some fun color  Super-glue the washer to the
 Slice the balloon such that just the outside edge of the chassis
middle is left, creating a thick rail, such that the axel hole in the
rubber-band shape wood is visible through the washer
 Force balloon band around the  the use of washers will minimize
outside lip of the CDs the contact surfaces – and they
 These may be added to none, give your car a nice finished look
some, or all wheels; or you may  Another suggested alternative (not
even put multiple CDs underneath included) is adding ball bearings to
the balloon wraps really minimize any losses due to
wheel friction
 Another easy suggestion for  And of course, Don‟t forget your
customization is to wrap the cup license plate!
holder with ribbon or any light-
weight decorative material of your
choice

41. Steps 37-46: Adding Wheels & Cup
Holder
37. Insert a rubber grommet into the 42. Once the large gear is centered on
center of each of the 4 CDs the small one and there is enough
38. On the wheel axel away from the room on either edge for the
gears, insert a few spacers onto the wheels, glue the small gear to the
end of the axel and then “cap” it by rear axel
pushing the axel end through the
now rubber center of the CD
43. Take the flattened cardboard strip
39. Repeat step 38, using the opposite and curl it into a loop, such that it
end of the same axel; this is now the once again looks like the center of
front wheel assembly 39
. a tape roll
44. Apply glue along the seem
adjoining the two ends of the loop;
this is now your cup holder
45. Place the cup holder on the top
surface of the chassis platform, in
40. Attach the last two wheels to the 2nd the middle of the front wheel
wheel axel to form the rear wheel assembly
assembly in a similar manner as the
front wheel assembly 46. Ensure the cup holder edges are
not in contact with any moving
41. Once the rear wheels are attached parts of the vehicle and then
41
to it, the wheel axel or the small gear . secure the cup holder on the
40
in the middle of it, may need to be
.
chassis with glue along the bottom
shifted; spacers may need to be edge
added/removed to either side to
adjust

42. Steps 47-52: Affixing the Break
47. Using pliers, Insert the threaded 50. Insert the round wooden rod into
rod into the end of the hollow axel this whole and glue at the seem
in the front wheel assembly, on between the rod and the chassis
50
the side of the vehicle opposite of .
the large gear side; turn and tap
in to ensure a tight fit
48. Next, measure 3 inches from the
threaded rod (or the center of the
CD), in the direction of the rear 51. Glue one wing of the wing nut
wheel assembly and make a onto “the break” (the small thin
mark; keep it at approximately strip of wood provided) and let
the same vertical height as the dry
axel
47
.
52. Once the wooden rod and strip
are stuck in place, the wing nut
can be screwed onto the
threaded rod sticking out of the
49. Using the drill bit, manually turn front axel; note when spun, the
the bit by hand into the soft balsa
49 52
rod should come into contact with
wood at the marked location, until. the break .
a whole is made through the side
rail

43. Using the Vehicle
 Once all of the assembly steps have been followed and all
glued joints are dry (we recommend over-night), your new
mousetrap powered vehicle is ready to be tested out
Drive Spin wheel Release
train forward to gear to see
starting engage it zoom
location spring forward
To set the break up, tighten the wing nut Feel free to
by spinning the wheel, until the break
engages, then untwist the wing nut and
deliver the
count the number of turns the CD makes beverage of
Translate the # of turns into feet of travel your choice, up
with our translation sheet provided to 44oz

44. Reference Sheet
# Turns 0.8 1.6 2.4 3.2 4.0 4.9 5.7 6.5 7.3 8.1 8.9 9.7 10.5 11.3 12.1 12.9
Dist (ft) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Use 32 Oz for 16‟ Runs
For 12‟ or Shorter Runs use 40 Oz
The Good:
•¼ Turn for 11‟ Empty
•1/3 Turn for 16‟ Empty
•2nd Spoke for 11‟ Loaded
•¼ Turn for 6‟ Loaded
The Bad:
•Start Bad with offset of 1‟ to the left for 16‟
•2nd Spoke for 11‟ Empty
The Bad & The Ugly:
•Need Full power when Loaded