D4E1 Woesh Juggling System

Welcome to our tutorial on building a custom System tower for people with disabilities. This project was created for the #Woesh Circus Atelier, a group that helps people with disabilities participate in #circus activities and performances, partnering with #HOWESTIPO and #D4E1. In this step-by-step tutorial, we'll show you how to build a sturdy, versatile juggling system that meets the demands of our target audience by providing stability, usability, and smooth rotation. Let's get started!

The juggling system is designed to be used by people of all abilities. Its smooth rotation, facilitated by bearings, allows users to interact with it effortlessly. To play, individuals simply push the balls attached to the tower, initiating a rotation around the steel tube. As the balls move, they create a dynamic and engaging experience, encouraging users to interact with the tower in various ways. Whether it's practicing juggling skills, improving hand-eye coordination, or simply enjoying the sensory feedback of the rotating balls, the juggling system offers a fun and inclusive activity for everyone to enjoy.

Ricca De Roose, Oguzhan Tekes and Bhavya Acharya

Tools:

• Band grinder
• Bandsaw or hacksaw
• Sandpaper
• Utility knife
• Glue gun
• Super glue

Materials:

• 1m of 20mm steel tube
• 300mm of 32mm PVC tube x3
• 725mm of 32mm PVC tube
• 32mm PVC T-joint x3
• 32mm PVC end caps x3
• 8mm Plywood sheet
• Umbrella stand suitable for 32mm PVC
• Six bearings (32mmx20mmx7mm)
• Acetone
• Styrofoam balls x3
• Pool noodle
• Spray paints

Here are the subassemblies before the main structure assembly:

1) Preparing the 20mm Steel Tube

2) Attaching Ball Bearings with T-joints

3) Making Extension Tubes with Styrofoam Balls and Pool Noodles

4) Preparing the Steel Tube End

These subassemblies are essential steps in preparing the various components required for the final assembly of the juggling System.

For the first step of smoothing the 20mm tube by sanding and polishing it;

1. Check its external diameter. This can be done using a vernier caliper or bypassing the bearing through the tube. Ensure that the tube's diameter is uniform and fits the specifications required (19mm - 20mm) for smooth rotation and movement. This initial measurement is crucial for determining the amount of sanding and polishing required to achieve the desired smoothness and finish.
2. Sand the steel tube to achieve the desired diameter using 80/120 grid sandpaper.
3. Finish the process by sanding the steel tube using 400-grid sandpaper. This will help to achieve a smooth and uniform surface texture, enhancing both the tube's appearance and functionality. Alternatively, you can opt for a spray glossy varnish finish to add a protective layer and further enhance the tube's aesthetic appeal.

The second step is attaching the ball bearings with the T-joints;

1. Clean the outer rings of the bearings with acetone to remove any grease. This step ensures direct contact between the metal and PVC surfaces.
2. Use super glue to fix two ball bearings per T-joint at two ends of the T-joint.

*Tip- use an external tube to support the bearing and then fix the T-joint with it.

For the third step of making the extension tubes attached with Styrofoam balls and pool noodles, follow these instructions:

1. Cut 3x 32mm PVC tubes with a length of 300mm.
2. Sand the ends of the PVC tubes using 400-grid sandpaper to smooth any rough edges.
3. Mark the surroundings of the PVC end cap on the Styrofoam ball.
4. Remove the Styrofoam material from the ball to fit the PVC end caps in them. Make them slightly deeper to hide the PVC end sticking out and ensure a snap fit around the PVC end cap.
5. Use super glue to stick a PVC end cap to one end of the PVC tube. Ensure a secure bond between the PVC end cap and the tube.
6. Hot glue the Styrofoam ball onto the PVC end cap. Press the ball against the PVC end cap firmly to secure it in place.
7. Cut three Pool noodles with a length of 250mm using a utility knife.
8. Make a silt on it to cut the noodles in half again using a utility knife.
9. Fit the Pool noodles on each of the PVC tubes.

For the last step, creating the steel tube end:

1. Take a sheet of 8mm plywood and lay it in the laser cutter.
2. Upload the file containing the design of the steel tube end to the laser cutting software.
3. Adjust the settings in the software according to the material and thickness of the plywood.
4. Start the laser cutting process to cut out the required shapes.
5. Ensure that the result includes four solid circles and four hollow circle cutouts as per the design.

Piece 1:

1. Take the four solid cutouts and two hollow ones.
2. Stack them with two hollow cutouts on the top and four solid ones on the bottom.
3. Apply wood glue between each layer and clamp them together securely.
4. Wait until the glue dries completely.
5. Once the glue has dried, chamfer the end with the solid cutout using a band grinder. Alternatively, you can cut the ends using a band saw before sanding directly for a more uniform shape.

Piece 2:

1. Take the remaining two hollow cutouts.
2. Apply wood glue between the two hollow cutouts and clamp them together securely.
3. Allow the glue to dry completely.
4. Once the glue has dried, chamfer one end using a band grinder.

Just in case, before the glue, make sure that the part fits perfectly inside the tube. If it does not, sand it with sandpaper.

Use super glue to stick piece 1 on one end of the steel tube. While the components already have a snap fit, it's best to glue them for added security. Allow the glue to dry completely before proceeding with further assembly. This step ensures that the steel tube end is securely attached.

Here's the assembly process:

1. Tighten the PVC Tube in the Stand:

Secure the 32mm x 725mm PVC tube in the stand, ensuring the bottom end touches the bottom of the stand for stability.

2. Insert the Steel Tube into the PVC Tube:

Insert the steel tube into the PVC tube, ensuring that the wooden piece snaps snugly into the PVC tube.

Level the top of the steel tube with your eye level to estimate the height.

3. Lock the Steel Tube with the Wooden Cutout Ring (Piece 2):

Pass the wooden cutout ring from the top of the steel tube and lock the steel tube with the top of the PVC tube. This minimizes wiggling in the structure and provides added stability.

4. Sliding the T-Joints to the Steel Tube:

Pass the T-joints from the top of the steel tube to the desired height. There may be some resistance while pushing, but the T-joints will stay in place when released at their required height.

5. Attach the Tube Extensions to the T-Joints:

Attach the tube extensions with the T-Joints to complete the assembly.

Once assembled, the juggling system is ready for use. Enjoy practicing and refining your juggling skills with this sturdy and functional structure!

Depending on the theme, several colors can be used. However, we have chosen to use black as the primary color with white touches. And individually for the balls, blue, purple and orange. Follow these steps to achieve the desired colors:

Base Coat:

• Start by spraying all the components, except the steel tube, with black matte spray paint.
• Allow the black base coat to dry completely.

Adding White Spots:

• Use a brush to create white dots over the pieces.
• Swing the brush lightly all over the components to achieve a scattered pattern of white spots.

Coloring the Balls:

• Use spray paints to color the balls.
• Use the assembled extension arms to facilitate the handling of the balls during the spraying process.

By following these steps, you'll achieve a visually appealing color scheme for the juggling system. Black is the base color, complemented by white spots and vibrant blue, purple and orange balls.