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MATERIALS
Popsicle sticks. [as many as needed]
3/4" Square Steel Stock 12" long, cut into a 4.5" piece (approximate) and a 7.5" piece (approximate)
2" x 4" x 10" wood (any kind); cut into two '4.5" long pieces (approximate)
#6-32 x 2" Machine Screw. [1]
#6-32 x 3/4" Machine Screws and Nuts Rounded head. [as many as needed]
Drill press.
9/64" Drill Bit.
Saw (band saw preferable; any will do).
Ruler.
Vise
Cut the 3/4" square steel stock into a 4.5' piece (exact) and a 7.5" piece (approximate), if not already done.
Mark center of holes on the 4.5" steel stock. Measure holes 4.00" apart and 2.83" apart (Figure 1). Measure from center to center. Drill through steel with the 9/64" bit. This will be the metal template for drilling holes into the Popsicle sticks.
EQUIPMENT
INSTRUCTIONS
Place the two wood blocks on their sides in the vise with the 8" piece of steel in between them (do not tighten the vise). Place Popsicle sticks in between the two blocks until near the top. Place the metal template on top of the sticks (Figure 2).
Align everything horizontally using another piece of wood. Then carefully press down on the template and tighten the clamp so that everything is in place.
Drill one hole through the template and through the sticks. Be careful not to break the bit. Place the #6-32 x 2" through the hole that was just drilled. The screw will help prevent horizontal movement among the sticks. Then drill the second hole either 4" apart or 2.83" apart from the first hole but not both.
Adjustment may be required to be certain that all the holes are lined up correctly.
Continue process until the required number of Popsicle sticks are finished.
Use the band-saw to trim off the ends of the short sticks. Approximate symmetry.
Build your trusses using the #6-32 x 3/4" machine screws and nuts.
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