How to Build a Hovercraft

October 2004
2
Patrick Wenzell
How to Build a Hovercraft
A Cobb County
Technology-Based Integration School

Special Thanks to
Mr. Joe Baker @
Dickerson Middle
School for the idea
October 2004
3
Patrick Wenzell
Primary Steps & Materials
Make Circular Platform
Work from Center to:
Drill holes per plan
Add riser for seating
Mount seating
Mount blower
Attach envelope
Duct Tape Edges
Cut & Attach Envelope
Paint as you wish
Required Materials:
4x4 Plywood
6x6 8mil Plastic
2x2 Plywood
12 Diameter Particle Bd.
1 x 3/8 Carriage Bolt/Nut
2 wood screws
Coffee Lid
Lots of Duct Tape
Sandpaper/Sanding Block
Paint



October 2004
4
Patrick Wenzell
Tape Measure
Tri-Square
Utility Knife
Chalk Line
Sandpaper/Block
and MATH SKILLS
Tools Required
Jig Saw
Circular Saw
String
Drill & Bits & Screws
Staple Gun & Staples
Paintbrush & guides

October 2004
5
Patrick Wenzell
Experimental Hovercraft
Goal:
Understand textual plans
Convert into a project plan
Manufacture components
Assemble components
Fine tune craft
Test and experiment
Create interactive experiments
What I learned:
How to outline a step by step plan
How to layout the plan on wood
How to use certain tools
How to make jigs to guide tools
How to troubleshoot problems
Not to get all my friends over to
see it work BEFORE I test it first

October 2004
6
Patrick Wenzell
Project Plan
Step 1
a. cut a 2 section of string (with a little extra).
b. tie the string to a pencil and the other to a tack or nail.
c. place the tack/nail in the center of the board.
d. keeping the string tight, draw a circle.
Step 2
a. cut a circle with a jigsaw.
Step 3
a. measure the diameter of your vacuums hose and drill the hole size accordingly.
b. drill a hole using the 1 or appropriately sized bit approximately 1 foot from the center of the hover craft.
Step 4
a. sand the edge of the disk on the top and bottom.
b. tape around the disk.
Step 5
a. drill a 11/4 hole in the center of the plywood for attaching the plastic skirt
b. cut the plastic sheet into a 54 x 54 square and lay it out on plywood disk
c. the carriage bolt washer coffee lid apparatus will be used to hold the plastic sheet to the plywood disk.
d. Poke small hole in the center of the plastic sheet.
e. Reinforce the hole with duct tape and then pass the bolt through the plastic sheet and bolt securely to the ply wood disk

October 2004
7
Patrick Wenzell
Project Plan (continued)
Step 6
a. trim the plastic sheet into a circle a little bit larger than the ply wood disk.
b. The plastic should be cut approximately 2 inches larger than the disk all the way around
Step 7
a. looking down on the hovercraft plastic side up draw 3 x3 squares on the plastic approximately 1 ft from
the center with 120-degree angles between each square.
b. The holes should not be directly above the hole where the shop vac will be attached
c. Space the shop vac hole between two of the square holes .
d. Use scissiors to cut
Step 8
a. over lap the plastic onto the opposite side of the ply wood disk leaving some play in the plastic .
b. staple the plastic to the ply wood on the top all the way around the disk leaving about 11/4 gap between
staples.
Step 9
a. wrap duct tape at least 2 times around the edges for protection.
Step 10
a. place chair centered on ply wood disk.
b. Place the shop vac or any blowing device (leaf blower/ air blower for air track behind the chair.
c. Connect the hose of the vacuum to blow the orifice and attach the other end of the hose to the hole on the
hovercraft.

October 2004
8
Patrick Wenzell
The Hovercraft Drawings
October 2004
9
Patrick Wenzell
Layout Circle on 4x4 Plywood
Find center of square
Tie pencil to nail in center of square
Adjust string to desired radius
2 = of diameter = 4 : 2*r = d
Draw Circle
Go ahead and layout:
Label Front/Back
Blower intake
Vent locations 120
o,

1 from center
At least 1 from Blower Intake
2 rear, 1 front

Lift Vents
Blower Intake
Center Point
120
o
120
o
120
o
BACK
FRONT
October 2004
10
Patrick Wenzell
Build a Jig to Guide Saw
Notch the end of a board to fit lip on
guide of saw
Drill hole to set blade at 2 from center
Hint, on a 4x4 square, center is exactly
2 from perpendicular sides
Nail to center of 4x4 sheet
Note: Safety Goggles & Mask
are required for protection!!!


October 2004
11
Patrick Wenzell
Cut a 4 Diameter Circle
Start at the edge
Slowly and evenly cut
the circle using the guide
Repeat to make even
October 2004
12
Patrick Wenzell
Smooth and Tape the Circle Edge
Sand the edges
100 grit
Round edges to protect plastic
Apply 3 layers of duct tape
Cut about 1 sections
Apply tangentially to Top
Fold over edges
Repeat from Bottom
Final layer center around edge
and seal top and bottom
October 2004
13
Patrick Wenzell
Everything Must Fit Smoothly
Drill 3/8 hole for carriage bolt in
center of circle
Drill hole for intake slightly
smaller than the diameter of the
blower
Sand the inside of the intake hole
to widen and make a very tight fit
Insert blower attachment
October 2004
14
Patrick Wenzell
Make Template, Build & Attach Riser
Riser is 2 pieces of scrap wood
Model with cardboard, first
Layout and cut notches to
provide access to center bolt
Notch both pieces to interlock
for strength and stability
Screw in from bottom

October 2004
15
Patrick Wenzell
Center Seat on Riser
Sand Interlock between Riser
components
Must be smooth
Must be level
Center 12 Seat on Riser
Attach with Screws into the riser
Can cover seat with foam
or just paint
October 2004
16
Patrick Wenzell
Cut Plastic 2-3 Larger than Platform
Plastic provides the Envelope
to provide lift for hovering
Set the platform on plastic
Cut circle around platform
about 3 from the edge
Use scissors or utility knife
October 2004
17
Patrick Wenzell
Attach Plastic Envelope
Fold edges a couple of times for
strength
Staple every to edge
Reinforce center and perimeter of
plastic with duct tape
Puncture small hole to receive 3/8
carriage bolt
Attach Coffee Lid
Secure with coffee lid, washer & nut

October 2004
18
Patrick Wenzell
More Duct Tape
Duct tape, same as before
over the stapled plastic
Mount 100mph blower


October 2004
19
Patrick Wenzell
Cut Holes for Lift Factor
Place platform upside down
Center plastic over platform
Draw 3 - 3 squares on the
plastic approximately 1 ft from
the center at 120-degree angles.
The holes should not be directly
above the intake hole where the
blower will be attached 1
away
Use 3 square template tied to
1 string & utility knife

October 2004
20
Patrick Wenzell
Reinforce Holes More Duct Tape
Tape edges of square cutouts
Tape front and back of edges
3 pieces of tape
Tape edge of cutout, then fold
over to reinforce inside
Especially the corners of the
cutouts
Tape Coffee Lid Washer
Around and across
October 2004
21
Patrick Wenzell
Ready for Testing & Tuning
Do Not Call Your Friends, Yet!

Two people lift platform
Another removes sawhorses
Place gently on clean floor
Test first w/o pilot
Test next w/light weight pilot
UP & DOWN ONLY!!!!!!!!!!
For now..
October 2004
22
Patrick Wenzell
Problems Encountered
Problem
Coffee can lid washer
collapsed
Blow out on side
5 lift in back, 3 in front
Bumper creates imbalance
Blow out creates imbalance
Solution
Re-attached/Re-inforced w/
Duct Tape
Patched with Duct Tape
Reduced back to 3 lift
Removed bumper
Fixed blowout with tape
October 2004
23
Patrick Wenzell
The Hardest Part of this Project was

October 2004
24
Patrick Wenzell
The Most Fun I Had With This Project was: