Woodworker's Journal 101-Projects-for-Woodworkers, страница 235
This little whale provides plenty of amusing action as his mouth opens and closes and his body pivots up and down when he is pulled. Make a few for gifts, or set up for production and market them to toy and gift shops.
Enlarge the grid pattern on cardboard and transfer the shapes of the tail and body to %" pine or maple. Jigsaw the two separate body sections, terminating in a semicircle with a 1" radius.
The half-lap cuts are started with a 2" hole saw chucked into an electric drill. Locate the pivot point or center of the circle on each part, and start the center bit of the saw into the mark. Cut %" deep, then remove the saw and cut away waste with a chisel.
Test the joint for a loose action by holding the parts together and moving them up and down. Shave a bit from each part until the joint pivots freely. Clean up the joint with sandpaper and secure the pieces with a brass I" »8 flat-headed screw. Drive the screw into a countersunk hole and back off until the joint is free. Then file the protruding tip of screw flush.
The lower jaw is made of pine sandwiched between two pieces of %" hardwood. The center piece should be cut to provide a recess for the upper jaw when the mouth is closed. Drill the pin hole through the main body, making it slightly oversize for a loose fit of a H" pin. The lower jaw should be drilled for a light fit over the pin.
Drill the body for a loose fit of the wheel axle. Use a hole saw to cut 2" discs from %" stock. Drill off-center holes part way into each disc, run the axle through the body, and glue the wheels to it. The center hole in the wheels can be plugged.
Give the toy a very thorough sanding and finish with two coats of penetrating-oil finish. The pull cord is inserted into a hole in the top of the head and secured with a small peg glued into the hole.