Truck Project Full Assembly – Page 1

Read me?

To help with your Truck Project, the Prototyping Basics

manual will give you instructions on how to safely use the
equipment in the Engineering Student Machine Shop.

Truck Project Prototyping Basics Manual – Page 2

 Note: K, N, O and P not shown.

B
J

C
Front View Side View

G G
E A

M
D F

Close-up of Axle Close-up of Bumper

Assembly Assembly

Bottom View

Truck Project Orthographic Projections – Page 3

 Part Qty . Name Description
A 1 Chassis 4-1/4" x 6-7/8" 16/18 Gauge Steel
B 1 Cab 1-7/8" x 2-3/4" x 3-9/16" Poplar Wood Block
C 1 Wheels (4) 1/2" x 1-1/2" x 6" MDF
D 2 Axle #8-32 x 5-3/8" Threaded Rod
E 8 Axle Nut #8-32 Hex Nut
F 8 Axle Flat Washer #8 Flat Washer
G 10 Axle/Bumper Lock Washer #8 Split Lock Washer
H 1 Bumper 1/2" x 1/2" x 2-3/4" Steel
I 2 Bumper Machine Screw #8-32 x 1/4" Pan Head Machine Screw
J 1 Bed 4" x 5-1/8" 16/18 Gauge Aluminum
K 1 Bed Liner 1/4" x 2-3/4" x 2-13/16" Plywood
L 4 Cab Screw #6 x 3/4" Wood Screw
M 4 Bed Rivet 1/8" Blind Aluminum Rivet
N 1 Bed Liner Tape 2" Strip of Double Side Tape
O 1 Sanding Block 1/2" x 2-1/2" x 4" MDF
P 1 120 Grit Sanding Paper 5-1/2" x 9" 120 Grit Sanding Paper

Truck Project Bill of Materials – Page 4

 Step I – Using Part A, layout* the lines shown in Step II – On the same part, layout the hole locations
the figure below. shown in the figure below. Note that the
locations are symmetrical about the Centre Line.

CL

* For information on part Layout, see Chapter 5.0 in Prototyping Basics.

Truck Project Step 1 – Chassis Build – Page 5

 Step III – To prep for drilling*, use a Centre Punch
to mark each location.

Step IV – At the 4 locations marked in red, use a

#30 Drill Bit to drill a 0.1285” diameter
through hole. Remember to use sacrificial
backing and to clamp both pieces with 2
clamps. KEEP YOUR HANDS AWAY WHEN
DRILLING. Drill slowly and try to maintain a
constant downward velocity.

Step V – At the 10 locations marked in yellow, use

a #16 Drill Bit to drill a 0.177” diameter
through hole. Remember to use sacrificial
backing and to clamp both pieces with 2
clamps. KEEP YOUR HANDS AWAY WHEN
DRILLING. Drill slowly and try to maintain a
constant downward velocity.

Step VI – Use a Deburring Tool on the backside of

each drilled hole to clean up any tear-out.

* For information on Drilling, see Chapter 6.0 in Prototyping Basics.

Truck Project Step 1 Continued – Chassis Build – Page 6

 Step VII – Use the Metal Cutting Vertical
Bandsaw* to cut out the perimeter waste
material.

Step VIII – Use a flat File to clean up the cut-out

lines as well as remove any burrs.

Step IX – Using the Brake**, bend the 4 Axle tabs

and the 2 Bumper tabs up 90°.

Your Chassis should look like this

* For information on using the Vertical Bandsaw, see Chapter 8.0 in Prototyping Basics.
** For information on using the Brake, see Sections 10.7 - 9 in Prototyping Basics.

Truck Project Step 1 Continued – Chassis Build – Page 7

 Step I – Using Part B oriented on its side, layout
the lines shown in the figure to the right.

Step II – Using the Wood Cutting Vertical

Bandsaw, cut out the waste material.

Step III – Using the 120 grit Sandpaper, sand the

freshly cut surfaces till flat and smooth.

Step IV – Lastly, use the 120 grit Sandpaper to

round over the edges and corners.

Your Cab should look like this

Truck Project Step 2 – Cab Build – Page 8

 Step I – To make the Wheels, start with Part C and Step IV – Use the Wood Cutting Vertical
layout the lines as shown below. Bandsaw or the Scrollsaw to roughly cut
out each Wheel. Be sure to use a push
Step II – Use a Centre Punch to mark the centre of stick when doing so. It’s okay if your
each Wheel. Wheel looks more like a polygon than a
circle but the more time you spend
Step III – Use a #16 Drill Bit to drill a 0.177” cutting, the less time you’ll spend
diameter hole through the centre of each sanding.
Wheel.

Truck Project Step 3 – Wheels Build – Page 9

 Step V – Gather together one of the Axles (Part D), 2 Step VIII – Tighten your assembly with a pair of
Axle Nuts (Part E), 2 Axle Flat Washers (Part F), 2 adjustable Wrenches to ensure they don’t
Axle Lock Washers (Part G) and the 4 Wheels. spin.

Step VI – Gang the Wheels together and insert the Axle Step IX – Insert the long end of your assembly
through all 4. At each end add a Flat Washer, a into the Drill Chuck as shown below and
Lock Washer and a Nut. Make sure the Lock use the Drill Chuck Key to tighten.
Washer is sandwiched between the Flat Washer
and the Nut. Please note that because the Axle
has been cut from a longer length of threaded
rod, there may be some burrs at the ends
that may obstruct with adding the Nut. If this is
the case, use a flat File to add a bevel to the
ends to help.

Step VII – Ensure the long end of your assembly is 2”

long. Your assembly should look like the figure
below.

E G F

2”

Truck Project Step 3 Continued – Wheels Build – Page 10

 Step X – Using the 120 grit Sandpaper provided,
wrap it around the Sanding Block (Part P)
as shown on the right.

Step XI – Apply pressure to the Sanding Block by

gripping the Sanding Block on its edges.

Step XII – While running the Drill Press at 500 End View
RPM or less, apply the Sandpaper wrapped
Sanding Block to the ganged Wheels in an
effort to make them round and the same
size. Be careful not to apply too much
pressure and let the Sandpaper do the
work. Be aware that the ganged Wheel
assembly will deflect, causing the Wheels
closer to the chuck to become round
quicker. As a result, you may have to focus
more sanding time on the bottom Wheels
in order to get all 4 Wheels the same size.

Step XIII – Once all 4 Wheels are round and equal

in size, you’re done.

Your Wheels should look like this

Truck Project Step 3 Continued – Wheels Build – Page 11

 Step I – Take a flat File and smooth the edges and
corners of the Bumper (Part H).

Step II – As shown on the right, layout the

following hole locations on the Bumper.

Step III – To be certain, double-check that the

hole locations of the bumper match-up
with the holes in the Bumper tabs. Adjust
location(s) if necessary.

Step IV – To prep for drilling, use a Centre Punch

to mark each location.

Step V – Drill and Tap* #8-32 holes at both

locations. You have the option of drilling
blind holes approximately 3/8” deep or
through holes at both locations.

Your Bumper should look like this

* For information on Tapping, see Sections 7.1 - 3 in Prototyping Basics.

Truck Project Step 4 – Bumper Build – Page 12

 Step I – Using Part J, layout the following lines as
shown on the right.

Step II – Use the Metal Cutting Vertical Bandsaw

or the Corner Notcher* to remove the
corner waste material.

Step III – Use a flat File to clean up the cut-out

lines as well as remove any burrs.

Step IV – Using the Brake, bend the 3 Bed tabs

up 90°.

Your Bed should look like this

* For information on using the Corner Notcher, see Section 10.5 in Prototyping Basics.

Truck Project Step 5 – Bed Build – Page 13

 Step I – The Bed Liner (Part K) has been cut to
rough dimensions. Check to see if it fits
inside the Bed.

Step II – If the Bed Liner fits nicely inside the Bed,

you’re finished Step 6. If it doesn’t fit,
depending on how much material you need
to remove, use a flat File, the Sanding Block
or the Wood Cutting Vertical Bandsaw to
remove excess material.

Note: Do not remove the backing to the double-

sided tape and adhere the Bed Liner to the Bed at
this point. This comes in Step 11.

Your Bed Liner should fit like this

Truck Project Step 6 – Bed Liner Build – Page 14

 Step I – Remove the Bed Liner from the Bed. Next,
orient the Chassis on top of the Bed as
shown on the right. When you’ve got it
exactly where you want it, clamp the two
pieces together, making sure not to cover
up any of the holes. Double check that the
Bed is centered and parallel with the
Chassis and the ends meet up nicely.

Step II – Use a Transfer Punch or a sharp pencil to

mark the hole onto the underside of the
Bed.

Step III – Unclamp the 2 pieces in order to focus

on the Bed. To prep for drilling, use a
Centre Punch to mark the centre of each
hole. You may want to put a piece of 2x4
material inside the bed when doing this in
order to give it some support, as shown on
the right.

Truck Project Step 7 – Bed/Chassis Assembly – Page 15

 Step IV – At the 4 locations marked, use a #30
Drill Bit to drill a 0.1285” diameter through
hole. Remember to use sacrificial backing
and to clamp both pieces.

Step V – Using the Riveter*, populate the 4 holes

that bind the Bed to the Chassis with the
1/8” aluminum Rivets (Part M) provided.
Make sure that you push the Rivets
through both pieces from the Bed side so
that the flat top of the Rivet is inside the
Bed, as shown below.

Your Bed/Chassis Assembly

should look like this

* For information on Riveting see Sections 10.10 - 12 in Prototyping Basics.

Truck Project Step 7 Continued – Bed/Chassis Assembly – Page 16

 Step I – Attach the Bumper to the Chassis using 2
Bumper Machine Screws (Part I) and 2
Bumper Lock Washers (Part G) in the order
shown to the right.

Your Bumper/Chassis
Assembly should look like this

Truck Project Step 8 – Bumper/Chassis Assembly – Page 17

 Step I – Orient the Chassis on top of the Cab as shown
on the right. When you’ve got it exactly where
you want it, clamp the two pieces together,
making sure not to cover up any of the holes.
Double check that the Cab is centered and
parallel with the Chassis.

Step II – Like in Step 7, use a Transfer Punch or a sharp

pencil to mark the 4 hole locations onto the
underside of the Cab.

Step III – Unclamp the 2 pieces in order to focus on

the Cab. To prep for drilling, use a Centre Punch
to mark the centre of each hole.

Step IV – Drill an appropriately sized Pilot Hole* at

each of the 4 locations to a depth of 3/4”.

Step V – Using the appropriate Screwdriver, screw the

4 Cab Screws (Part L) into the locations marked
with a red circle.

Your Cab/Chassis Assembly

should look like this

* For information on selecting Pilot Holes sizes for Wood Screws, see Table 12-4 in Prototyping Basics.

Truck Project Step 9 – Cab/Chassis Assembly – Page 18

 Step I – Gather together one of the Axles (Part D),
4 Axle Nuts (Part E), 4 Axle Flat Washers
(Part F), 4 Axle Lock Washers (Part G) and
2 Wheels.
C
Step II – Thread the Axle through the holes in the
2 rear wheel tabs of the Chassis. Assemble
the Wheels onto the Axle in the order E
shown to the right. Make sure the Lock
Washer is sandwiched between the Flat
Washer and the Nut. D

Step III – Repeat for the front Axle.

F
G

Your Wheel/Axle/Chassis
Assembly should look like this

Truck Project Step 10 –Wheel/Axle/Chassis Assembly – Page 19

 Step I – Remove the backing from the Bed Liner
Tape provided and place it in the middle of
the Bed.

Step II – Gently place the Bed Liner into the Bed in

the orientation you like. Press down on the
Bed Liner so that it compresses into the
double-sided tape, making a good bond.

Your Bed Liner/Bed Assembly

should look like this

Truck Project Step 11 – Bed Liner/Bed Assembly – Page 20

 Now, put it on the ground and let’r rip!

Truck Project Finish Line – Page 21