Creation Club is a build shop. A Founding Day, then twenty five build sessions with three options every week, one 65 minute rhythm that never changes, and a rank ladder that hands the room to the learners by spring. Kindergarten through eighth grade, one guide, no floater.
Every activity ships with guide prep, an itemised supply list, what to show at the Shop Meeting, a step by step guide-led build, the two things that usually go wrong, and what to do if the room is running fast or slow. The test is whether someone covering for you could run it cold.
26Sessions
78Build options
65Minutes each
K–8All ages
$1,113Full year, recommended plan
$139Per learner at 8
01
Founding Day
Before anything gets built, the room gets its rules. Founding Day is Day 1 of the club, separate from the 25 build sessions, and it never repeats: new joiners at sessions 6, 11, 16, and 21 don't relive it, their Shop Buddy walks them past the posters instead.
The one thing that has to happen first
All Acton Silicon Valley rules still apply here.
Creation Club does not get its own separate rulebook that replaces the school's. Hallway expectations, respect for people and space, how conflict gets handled, all of it still applies in the shop. What Founding Day adds is a second, more specific layer on top: what safe, creative, kind, and clean looks like at a table with box cutters and hot glue.
The contract, built by the room, not handed to it
The guide draws four columns on the board (Safe, Creative, Kind, Clean) and asks one question per column. The rules go up in the builders' own words. A contract nobody would veto is not tested yet, so the guide asks explicitly before anyone signs: is there anything here you would not actually agree to?
Why it's built live, not pre-written
A guide-written list that the room approves is a listening exercise, not a contract, and it will not hold in October when nobody remembers agreeing to anything. The rules have to come out of their mouths, four to six of them total, one or two per pillar. More than that and nobody remembers it by session 6.
Why it becomes a poster, not a memory
Membership can change any given week, so the rules cannot live only in the room's memory. Two builders letter the pillar headers while the contract is still being written, the final wording goes up in marker large enough to read across the room, everyone signs it, and it hangs permanently where every future session starts.
The full guide script, the four pillars, and the poster process are laid out below, exactly as they appear in the guide binder, alongside the three nametag build options.
02
How a session runs
Same 65 minute rhythm every week. That repetition is the mechanism that makes the handoff possible: by session 16 a learner can run this because they have watched it happen fifteen times.
5Shop Meeting
6Sketch & Spec
40Build & Test
5Reset
4Shop Talk
5Flex buffer
Minutes 0 to 5
Shop Meeting
Circle up. The Socratic question goes on the board and no adult answers it. Then the Challenge Card and the inspiration. Every activity has a Show them first list of three things, with instructions to pick one, not all three. Five minutes is short and the list is built for it.
Minutes 5 to 11
Sketch & Spec
No cardboard touched. Everyone draws their build and labels one thing they think will fail. Six minutes, non-negotiable, and the single biggest quality lever in the program. Builders declare here which bench they are on and whether they are taking Pro Spec.
Minutes 11 to 51
Build & Test
Build and test share the block because they are the same activity. Test Bench stays open the whole 40 minutes, run by the Test Captain, so a builder can test at minute 15 and again at minute 38. One Freeze call at the halfway mark: 60 seconds where everyone looks at three other builds and steals one idea.
Minutes 51 to 60
Reset, then Shop Talk
Reset Crew runs cleanup, 5 minutes, shop closes clean or it does not close. Then 4 minutes of Shop Talk: two questions, asked once, answered by learners. No praise from the adult, because praise from the adult ends the thinking.
The two benches
Open Bench and Guided Bench
From Sketch & Spec through the end of the build the room splits. Open Bench works independently from the Challenge Card alone: the Spec is the adult. Guided Bench is a small group walked through a simple, known-good version of the same build, step by step. All 75 activities include written Guided Bench steps, so a solo guide always has something concrete to run.
Guided Bench is opt-in and never assigned by grade. A second grader can be on Open Bench and a seventh grader can be on Guided Bench, and both are fine.
It is also the cleanest handoff lever in the design. Running Guided Bench is a defined job with a script, which makes it exactly the thing a Lead Builder can take over. From Arc III onward an older learner runs Guided Bench and the guide floats. That is what leadership looks like for a sixth to eighth grader here, and it is why the age question resolves itself.
Solo guide reality check
What one adult can actually hold
With no floater the guide can only be in one place. Open Bench is built to run without an adult: the Challenge Card carries the whole assignment, Test Bench is learner-run from session 6, and the No Rescue rule routes help to peers. The guide's physical position during the 40 minute block is at the Guided Bench, with the glue guns and cutters staged there.
Sessions 1 to 5: guide runs Guided Bench. Sharp tools live at the guide's table only.
Sessions 6 to 10: Test Captain and Stock Keeper come online, removing the two things that interrupt a guide most.
Sessions 11 onward: a Lead Builder runs Guided Bench and the guide circulates for the first time all year.
Prep is the other half of the answer. Every activity page lists what to cut, punch, or pre-roll beforehand, with a time estimate. Most range from 10 to 30 minutes. Skipping it does not make the session shorter, it makes it fail: 60 traced-and-cut wheels is the difference between session 2 working and session 2 being 40 minutes of cutting circles.
03
Entry points, ranks, and the handoff
Entry points
Designated Open Shop sessions: 1, 6, 11, 16, and 21. Advertised to families. Each is architected so a brand new builder has a complete, successful, self-contained experience on day one.
Between entry points learners can still join. Every build is self-contained. A mid-arc joiner gets a Shop Buddy at the door, runs their Shop License during Sketch & Spec, joins Guided Bench for their first session, and gets the same Challenge Card as everyone else. Late joiners after session 16 cannot pitch a build until they have completed two sessions, but they can co-build immediately.
The real chaos control is stations, not dates. The shop has a fixed number of build stations. When they are full they are full, and the waitlist rolls to the next Open Shop. A natural consequence learners understand, and a number the Shop Council can manage themselves.
The Shop License and the rank ladder
Ranks are age-blind. A third grader can outrank a sixth grader. That happens, it is fine, and it is extremely good for the culture.
Shop License · earned session 1, or on arrival
Demonstrate the three core cuts: score and fold, slot, notch
Name the two safety rules and the one cleanup rule
Sign the Shop Book
Rank 1 · Builder
Has a license. Builds, tests, resets.
Rank 2 · Certified Builder
Three builds passed at Test Bench, one at Pro Spec
Taught the Shop License to one new builder
Unlocks: takes Apprentices, holds a shop job, votes in Shop Council
Rank 3 · Lead Builder
Certified, plus ran a Test Bench station solo
Ran the Guided Bench for one full session
Led a Shop Talk: asked the two questions, held the silence, answered for nobody
Rank 4 · Shop Lead
Ran a full session end to end with a guide present but silent
Wrote a Challenge Card another builder successfully built from
Unlocks: runs sessions 21 to 25, returns next year as founding Shop Council
The handoff ladder
Phase 1
Sessions 1 to 5 · Guide runs the shop
Guide holds the Guided Bench. Only learner responsibility is Reset Crew.
Guide 100%
Phase 2
Sessions 6 to 10 · Jobs go live
Five standing jobs rotate weekly among Certified Builders.
Guide 80%
Phase 3
Sessions 11 to 15 · Guest Shop Lead
One learner runs Shop Meeting and Shop Talk from a prep card. A second runs Guided Bench. The guide circulates.
Guide 55%
Phase 4
Sessions 16 to 20 · Learners own the content
Learner-pitched builds. A Shop Lead pair runs the session. Guide owns materials, safety, and Test Bench.
Guide 30%
Phase 5
Sessions 21 to 25 · Learners own the shop
Shop Leads run everything including Test Bench. Shop Council handles the calendar, materials, and admissions.
Guide 10%
The honest risk: Phase 4 will wobble. A session will go badly. That is the curriculum, not a failure of it. The Recovery Cards turn a collapsed session into a real build, and the Shop Talk that follows is the most valuable one of the year.
Age and level: the two-spec system
Every build has a Spec any builder can reach and a Pro Spec that adds one constraint. The constraint changes the engineering problem rather than the size of it: no adhesive, hit a repeatability target, work to a measured tolerance. Handing an eighth grader a bigger version of a younger learner's project is condescending. Handing them the same build with "slot joints only, no tape" is a different problem, and a real one.
Scalability
1. The Shop Book
The printed binder: 78 activity pages, each with prep, supplies, Guided Bench steps, failure modes, and pacing. The bar is that a guide with no maker background runs session 7 cold from the page. That gets tested for real during sessions 11 to 15.
2. The materials system
A labeled wall with a par list, a donation pipeline, and a planning spreadsheet that recalculates the shopping list for any subset of sessions. Stock Keepers maintain it all year.
3. The rank ladder
Four to eight Shop Leads by session 25, who become next year's founding Shop Council. The program's continuity lives in the learners.
4. The pitch archive
Every learner pitch from sessions 16 to 25, including rejected ones. Next year opens with 20 or more pre-vetted, learner-authored builds on file.
04
Scope & sequence
Founding Day, then five arcs of five build sessions. Three options each, so the same curriculum can run three different years without repeating. The recommended option is in bold. The cost column is the range of per-builder materials draw across the options.
marks a designated entry point — Founding Day itself, plus sessions 1, 6, 11, 16, and 21. These are the six points advertised to families as times a new builder can join without disrupting the room; every build on those days is self-contained so a first-timer never walks into the middle of something. Between entry points learners can still join, they just get a Shop Buddy and their Shop License on arrival rather than a designated welcome day.
#
Session
Three options
$ per builder
Arc
Day 1
Founding Day
The Builder Medallion · The Standing Sign · The Jeweled Nametag
$1.17 to $1.58
Founding Day
01
First Cut
Arcade Opening Night · The Chair Test · Tower Trials
$0.18 to $0.65
Open Shop
02
Things That Go
Gravity Racers · Cargo Haulers · Balloon Racers
$0.29 to $0.94
Open Shop
03
Structures
Bridge Build · Shelter · Shelf That Ships
$0.24 to $0.54
Open Shop
04
Launch
Siege Engines · Vortex Cannon · Glider and Launcher
$0.23 to $0.67
Open Shop
05
Play
Tabletop Sport · Pinball · Tilt Maze
$0.50 to $1.25
Open Shop
06
Stored Energy
Wind-Up Machines · Spring Launchers · The Kinetic Domino
$0.39 to $0.90
Mechanism
07
Fluid Power
Hydraulic Arm · Hovercraft · Pneumatic Launcher
$0.83 to $2.33
Mechanism
08
Gears and Cams
Automata · Gearbox · Marble Clock
$0.52 to $1.18
Mechanism
09
Circuits
Paper Circuits · Steady Hand Game · Scribble Bots
$1.10 to $5.36
Mechanism
10
Linkages and the Handoff
Grabber Arms · Walkers · The Teaching Build
$0.44 to $0.74
Mechanism
11
Chain Reaction
Chain Reaction · The Machine That Does One Stupid Thing · Marble Wall
$0.66 to $0.94
Systems
12
Shared Worlds
The District · The Museum · The Track
$0.42 to $1.92
Systems
13
Synthesis
Arcade 2.0 · Vending Machine · The Gauntlet
$0.40 to $1.68
Systems
14
Scale
Scale · Wearable Engineering · Kinetic Sculpture
$0.52 to $1.02
Systems
15
The Pivot
The Arena · Shop Upgrade · The Commission
$0.98 to $2.06
Systems
16
Pitch Day
Speed Build: 20 Minute Challenge · The Redo · The Brief
$0.17 to $0.47
Commission
17
Learner Pitch, Week 1
The Fix · The Organizer · The Adapter
$0.64 to $1.16
Commission
18
Learner Pitch, Week 2
The Duel · The Record Board · The Handicap
$0.94 to $1.18
Commission
19
Learner Pitch, Week 3
The Gift · The Toy · The Demo
$1.12 to $1.66
Commission
20
Learner Pitch, Week 4
The Combo · The Upgrade · The Black Box
$0.43 to $1.99
Commission
21
Entry Point and Shop Reset
The Onboarding Build · The Shop Rules · The Time Capsule
$0.39 to $1.99
The Shop Is Theirs
22
Learner Pitch, Week 5
The Two-Session Build · The Huge One · The Swarm
$0.57 to $0.67
The Shop Is Theirs
23
Learner Pitch, Week 6
The Expo Piece · The Drop-In Station · The Story Wall
$2.13 to $2.21
The Shop Is Theirs
24
Dress Rehearsal
The Full Run · The Stress Test · The Handover
$0.61 to $1.16
The Shop Is Theirs
25
The Build Expo
The Open Shop Expo · The Challenge Expo · The Commission Expo
$1.37 to $2.29
The Shop Is Theirs
05
The sessions
Founding Day first, with its contract and posters, then the 25 build sessions. Open any option for the full Challenge Card: Spec, Pro Spec, guide prep with time estimates, itemised supplies, what to show, the Guided Bench walkthrough, Test Bench setup, the two usual failures with fixes, and pacing for a room running fast or behind.
0 of 26 chosen
Arc 0
Founding Day
Sessions Day 1, once
Before anything gets built, the room gets its rules. Every learner who joins after today meets this same day in miniature.
Handoff
Phase 0: Guide runs the whole day. The contract and posters are the one artifact every future entry point depends on.
Note
This session never repeats. New joiners at sessions 6, 11, 16, and 21 don't relive it, they get walked past the posters by their Shop Buddy as part of onboarding.
Day 1
Founding Day
Entry pointArc 0
Shop Meeting question
What makes a rule worth agreeing to, instead of a rule you were just told?
Say this before anything else
Say this in the first two minutes, plainly, before anything else: every Acton Silicon Valley rule is still a rule in this room. Creation Club does not get its own separate rulebook that replaces the school's. Hallway expectations, respect for people and space, how conflict gets handled, all of it still applies here. What the club adds today is a second, more specific layer on top: what safe, creative, kind, and clean looks like specifically at a table with box cutters and hot glue.
Building the contract · guide script
Draw four columns on the board: SAFE, CREATIVE, KIND, CLEAN. Nothing else on the board yet.
Ask the room: "What's one rule that would make this shop safe?" Take three or four answers. Write them under SAFE in the builders' own words, not yours.
Repeat for CREATIVE: "What's one rule that protects everyone's chance to make their own thing?"
Repeat for KIND: "What's one rule about how we talk about each other's builds?"
Repeat for CLEAN: "What's one rule about how we leave this room?"
Read the whole board back out loud, as one contract, start to finish.
Ask: "Is there anything up here you would not actually agree to?" Cut or fix anything a builder pushes back on. A contract nobody would veto is not tested yet.
Every builder signs their name on the poster, in marker, right now, before any building happens today.
Safe
Tools are used the way they were shown. If something feels unsafe, you say so out loud, immediately, to any adult or Lead Builder.
Creative
Your build is yours. You can ask for help and you can borrow an idea, but nobody finishes it for you and you don't finish anyone else's.
Kind
You can criticize a build. You never criticize a builder. What you say about someone's work, you say to their face, not about them.
Clean
The shop closes clean or it does not close. That is everyone's job, every session, no exceptions for how good today's build was.
If the room stalls
Do not write the rules yourself and ask the room to approve them. That is not a contract, it is a listening exercise, and it will not hold in October when nobody remembers agreeing to anything. The rules have to come out of their mouths.
If a proposed rule is vague ("be careful"), push once: "Careful looks like what, exactly?" Vague rules do not survive a Shop Talk in March. Specific ones do.
If the room proposes something punitive ("if you break a rule you're out for a week"), redirect to what the rule protects rather than what the punishment is: "What would we actually lose if this rule got broken?" Consequences come from natural results, not a sentence.
Four to six rules total, one or two per pillar, is the right size. More than that and nobody remembers it by session 6.
Turning it into posters
Two builders letter the four pillar headers in large block letters while the contract is still being written, so the poster is ready to fill in the moment the words are final.
Transfer the final wording from the board onto the poster in marker, large enough to read from across the room.
Every builder signs it.
Hang it permanently on the wall where every future session starts, before builders arrive for session 1.
Make a second, smaller copy for the Shop Book, so the exact wording survives even if the poster gets damaged.
Why this has to be a poster, not a memory
This poster is the one artifact in the whole program that a first grader and an eighth grader both signed on day one, and it is what a Shop Buddy shows a new joiner at every entry point for the rest of the year: "Here's what we agreed to. You're signing it too." Because membership can change any given week, the rules cannot live only in the room's memory. They have to be on the wall, in writing, in words the builders chose.
With the contract signed and posted, there is time for one short,
fun build. Pick one of the three below.
Spec · everyone reaches this
Hangs around your neck on a cord and your name is legible from 5 feet away.
Pro Spec · opt in, never assigned by grade
Add one symbol for something you want to learn how to build this year.
Before the session · guide prep
Cut 20 chipboard circles ahead of time using a bowl template, about 4 inches across. A brand new builder should not be handed scissors and a bowl on day one. 15 minutes.
Pre-punch the hole in each circle near the top edge. 8 minutes.
Cut cord into 24 inch lengths, one per builder, knotted at one end so it doesn't fray. 10 minutes.
Wear a finished one yourself as builders arrive.
Guided Bench · The Circle Medallion
Say each step, wait, say the next. Do not build it for them.
Trace a large circle onto chipboard using a bowl as a template.
Cut it out.
Punch one hole near the top edge.
Write your name across the middle in big letters.
Decorate the border with gems or marker.
Thread the cord through the hole and tie it.
Show them first · pick one, not all three
Hold up an Olympic medal or a photo of one.
Show a conference name badge on a lanyard.
Wear a finished one yourself as builders walk in.
Test Bench
Everyone wears theirs out the door. If it's readable across the circle, it passes.
Core skill
Layering, hole punching, first use of the shop tools
Supplies
Item
Per builder
For 15
Chipboard (cereal box panel)
1 panel
15 panel
free / donated
Rhinestone or sequin sticker
6 gem
90 gem
consumed
Yarn or lanyard cord
2 ft
30 ft
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Materials draw $1.35 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Name is too small to read across the room. Draw one guide letter on the board at the actual size you want and have them match it.
Cord pulls out of the hole. Punch the hole at least half an inch from the edge, or reinforce it with a small piece of tape first.
Pacing
Running fast: Add the Pro Spec symbol, or add a second color layer behind the circle for a border.
Running behind: Skip the cord and just decorate the circle. It can sit at their table spot instead of hanging around their neck.
Spec · everyone reaches this
Stands up on its own and your name is legible from across the table.
Pro Spec · opt in, never assigned by grade
Add a moving part: a hinged flap, a spinner, or a pop-up piece.
Before the session · guide prep
Pre-cut 20 cardstock rectangles to a consistent size, about 5 by 7. 10 minutes.
Fold one yourself first and stand it up on the table where builders will see it as they walk in.
Practice the fold once before the session so you can demonstrate it in one smooth motion, not fumbling.
Guided Bench · The Tent Fold
Say each step, wait, say the next. Do not build it for them.
Fold a rectangle of cardstock in half like a tent.
Write your name on one face in big letters.
Fold small tabs out from the bottom edges so it stands without leaning.
Decorate with gems, marker, or cut-paper shapes.
Stand it up and test it.
Show them first · pick one, not all three
Show a restaurant table tent card.
Fold a plain sheet of paper into a tent while they watch.
Hold up a finished one standing on its own.
Test Bench
Set every sign on the table at once. Anything that falls over gets one fix and a retest.
Core skill
Score and fold, the first of the three core Shop License cuts
Supplies
Item
Per builder
For 15
Cardstock sheet
1 sheet
15 sheet
consumed
Rhinestone or sequin sticker
6 gem
90 gem
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.17 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Sign won't stand, it lies flat. The fold tabs weren't creased sharply enough. Run a fingernail or a ruler edge along every fold.
Sign leans and tips backward. Tabs are too short. Fold them out wider, at least an inch.
Pacing
Running fast: Take the moving-part Pro Spec: a hinged flap over the name that lifts up, attached with a small piece of tape as a hinge.
Running behind: Skip decoration entirely. A folded, named, standing card is a complete pass on the Spec.
Spec · everyone reaches this
Your name is on it and it is decorated with at least three materials.
Pro Spec · opt in, never assigned by grade
Add a second layer that sits raised above the base, so it has real depth, not just decoration.
Before the session · guide prep
Pre-cut a stack of assorted small shapes (stars, circles, squares) from spare cardstock so builders have something to layer on top without needing to freehand-cut a shape themselves on day one. 15 minutes.
Set out gems, sequins, and chenille stems in small shared bowls at each table before builders arrive.
Have one finished example with a visibly raised layer and one flat one, so the Pro Spec difference is obvious at a glance.
Guided Bench · The Layered Base
Say each step, wait, say the next. Do not build it for them.
Cut a rectangle or a shape of your choice from cardstock as the base.
Write your name across it in big bubble or block letters.
Glue a smaller cutout shape on top, raised, for depth.
Add gems, sequins, or chenille stems around the edges.
Punch a hole and add a cord if you want to wear it, or leave it flat for your table spot.
Show them first · pick one, not all three
Show a finished one with a raised layer versus a flat one, side by side.
Pass around a few loose gems and a chenille stem so hands are already busy.
Ask what one thing they want people to know about them this year.
Test Bench
Gallery walk. Everyone's nametag goes on the table and everyone looks at everyone else's.
Core skill
Layering, adhesive control, working from a personal design
Supplies
Item
Per builder
For 15
Cardstock sheet
2 sheet
30 sheet
consumed
Rhinestone or sequin sticker
8 gem
120 gem
consumed
Chenille stem (pipe cleaner)
1 stem
15 stem
consumed
Hot glue stick
0.5 stick
7.5 stick
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Yarn or lanyard cord
1 ft
15 ft
consumed
Materials draw $1.58 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Raised layer won't stay stuck down. Glue dabbed only in the center. Run a thin bead of glue around the whole edge of the layered piece, not just a dot.
Name gets lost under decoration. Write the name first, decorate around it after, never over it.
Pacing
Running fast: Take the raised-layer Pro Spec, or add a second raised layer for even more depth.
Running behind: One layer, three gems, name written large. That is a complete, decorated nametag.
Arc I
Open Shop
Sessions 1 to 5
Foundations. High success, fast wins, and the five techniques every later build depends on.
Handoff
Phase 1: Guide runs the shop. Only learner job is Reset Crew.
Note
Nothing here depends on a prior session. Any of these five can be dropped in mid-year for a new builder.
01
First Cut
Entry pointArc I
Shop Meeting question
What's the difference between a mistake and a failure?
Spec · everyone reaches this
Has a way to score and a way to return the ball.
Pro Spec · opt in, never assigned by grade
Two scoring zones worth different points, and the ball comes back to the player without them walking to get it.
Why this Pro Spec is reachable in 40 minutes
A scoreboard or ticket dispenser is a 3-hour build for an adult. A return channel is a folded cardboard trough taped at a downhill angle, which is about 6 minutes. Same engineering idea (the machine does something for you), one twentieth the build.
Before the session · guide prep
Build one skee-ball ramp yourself the night before. It is the exemplar and the Guided Bench demo. 20 minutes.
Pre-cut 8 shoe-box-lid ramps at a 20 degree angle so Guided Bench does not lose time on the first cut. 10 minutes.
Stage a bin of 20 assorted small boxes.
Guided Bench · Skee-Ball Ramp
Say each step, wait, say the next. Do not build it for them.
Cut a shoebox lid into a ramp.
Tape it inside a shoe box at an angle.
Cut three holes in the far wall.
Write 10, 20, 50 above them.
Tape a strip along each side so the ball can't fall out.
Roll a ping pong ball and adjust the ramp angle.
Show them first · pick one, not all three
Guide builds the skee-ball ramp beforehand and has it on the table, already working.
Play the short film Caine's Arcade (search: Caine's Arcade). Three minutes is enough.
Put a real arcade token or ticket on the table without saying anything.
Test Bench
Last 12 minutes, everyone plays everyone's game. A game that needs explaining fails.
Core skill
Box construction, slotting, playtesting
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
1 sheet
15 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Ping pong ball
1 ball
15 ball
buy once, reuse
Marble
2 marble
30 marble
buy once, reuse
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.65 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Ball jumps out of the ramp. Add 1 inch side rails the full length, not just at the top.
Holes cut too small so nothing scores. Trace around the actual ball plus a finger width before cutting.
Pacing
Running fast: Add a second ball size worth different points.
Running behind: Drop to one scoring hole. A one-hole game that works beats a three-hole game that does not.
Spec · everyone reaches this
Holds a builder for 10 seconds, no hands on the floor.
Pro Spec · opt in, never assigned by grade
No tape and no glue. Slot joints only.
Before the session · guide prep
Cut two 12x14 rectangles per Guided Bench builder ahead of time, and pre-mark the slot line. 12 minutes.
Have one finished X-base stool on the table, already holding a stack of books.
Guided Bench · The X-Base Stool
Say each step, wait, say the next. Do not build it for them.
Cut two identical rectangles about 12 by 14.
Cut a slot halfway down the middle of each, one from the top, one from the bottom.
Slide them together into an X.
Cut a 14 by 14 square for the seat.
Slot or tape the seat onto the X.
If there's time, add a second X underneath turned 90 degrees.
Show them first · pick one, not all three
Turn a real chair upside down and ask where the weight actually goes.
Search: cardboard chair design. Show three photos, no commentary.
Pass around a corrugated shipping pallet or a thick shipping box corner.
Test Bench
Progressive sit test, lightest builder to heaviest, until it fails.
Core skill
Layering, load paths, compression
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.18 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Slot cut too wide so the X wobbles. Cut the slot the exact thickness of the cardboard, then widen only if it will not slide.
Chair crushes straight down. The corrugation flutes are running sideways. Turn the panel 90 degrees so the flutes run up and down.
Pacing
Running fast: Take the no-tape Pro Spec, or add a back rest.
Running behind: Skip the seat panel and test the X-base alone under a stack of books.
Spec · everyone reaches this
Survives 10 seconds of box fan at 3 feet with the can on top.
Pro Spec · opt in, never assigned by grade
Material budget of 4 square feet, measured and enforced.
Before the session · guide prep
Pre-roll 10 tight cardboard tubes so Guided Bench starts with tubes in hand. 10 minutes.
Tape a height chart on the wall and mark 12, 18, 24, 30 inches.
Test the fan at 3 feet on your own build so you know what survives.
Guided Bench · The Tube Tripod
Say each step, wait, say the next. Do not build it for them.
Roll three tight cardboard tubes.
Tape them into a tripod.
Cut three short strips and tape them across the legs as cross braces.
Tape a flat square on top.
Stack a second tripod on top if there's time.
Show them first · pick one, not all three
Stand a flat sheet of paper on its edge, then roll it into a tube and stand it. Say nothing.
Search: Eiffel Tower base structure. Ask what all the triangles are for.
Show a truss bridge photo next to a plain plank.
Test Bench
Height measured, can placed, fan on. Countdown out loud as a group.
Core skill
Triangulation, bracing, center of gravity
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.18 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Tower falls before the fan even starts. There are no triangles in it. Add three diagonal braces.
Tower is tall but the can tips it. The top platform is too small. Widen it and check the can sits centered.
Pacing
Running fast: Take the 4 square foot material budget, or go for height with the same base.
Running behind: Set a 12 inch height target and get the can standing on it. That is a pass.
02
Things That Go
Arc I
Shop Meeting question
Should you copy a design that works?
Spec · everyone reaches this
Rolls straight for 6 feet with no push.
Pro Spec · opt in, never assigned by grade
Three runs that all finish within one car length of each other. Consistency, not speed.
Why this Pro Spec is reachable in 40 minutes
Half-second timing is beyond what a kid with a stopwatch can measure reliably, so the original Pro Spec was really testing the stopwatch. Distance clustering measures the same property and a tape measure cannot lie.
Before the session · guide prep
Cut 60 cardboard wheels using a jar lid as a template, or a hole saw. This is the one thing that will eat your session if you skip it. 25 minutes.
Build one straw axle car. Roll it across the table when builders walk in.
Set up the ramp: a 30 inch board or stiff cardboard propped 8 inches high, with a tape start line at the bottom.
Guided Bench · The Straw Axle Car
Say each step, wait, say the next. Do not build it for them.
Cut a cardboard rectangle for the body.
Tape two straws across the underside, front and back, parallel.
Push a skewer through each straw.
Push a cardboard circle onto each skewer end.
Glue where wheel meets skewer, never where skewer meets straw.
Roll test and fix the wobble.
Show them first · pick one, not all three
Guide's own straw axle car, rolling straight across the table on arrival.
Bring a toy car and turn it over. Look at the axle together.
Search: pinewood derby car. Ask why they all look like that.
Test Bench
Ramp, tape measure, bracket race. Then the consistency round.
Core skill
Axle mounting, wheel truing, friction
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Drinking straw
2 straw
30 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.29 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Car curves hard to one side. The two straws are not parallel. Re-tape them against a ruler edge.
Wheels spin but the car does not move, or wheels do not spin at all. Glue got into the straw. Wheels glue to the skewer only.
Pacing
Running fast: Take the consistency Pro Spec, or reduce weight and re-run.
Running behind: Two wheels and a front skid instead of four wheels. Still rolls, still races.
Spec · everyone reaches this
Moves 10 feet carrying any load.
Pro Spec · opt in, never assigned by grade
Swap the small spool for a large one and prove with a load test that the large spool pulls more weight.
Why this Pro Spec is reachable in 40 minutes
Building a gear reduction in 40 minutes is not happening. Swapping spool diameter is a 3 minute change that demonstrates the exact same mechanical advantage principle, and it is a real A/B test with a number attached.
Before the session · guide prep
Cut 60 cardboard wheels (see 2A). 25 minutes if not already done.
Save 10 empty tape roll cores as large spools, and cut 10 short tube pieces as small spools.
Set up a 10 foot taped lane and hang a load bucket over a table edge.
Guided Bench · The Spool Puller
Say each step, wait, say the next. Do not build it for them.
Build the straw axle car first.
Tape a spool (an empty tape roll core) onto the rear axle.
Tie a string to the spool and wind it up.
Run the string over the table edge with a weight on the end.
Let go and watch. Add weight until it stops.
Show them first · pick one, not all three
Search: elevator counterweight. One diagram is plenty.
Show a fishing reel or a yo-yo and let them work out why it winds.
Hang a bag of books off a string over a table edge before anyone sits down.
Test Bench
Loaded course. Weight added until it stalls. Number posted.
Core skill
Torque versus speed, spools, string routing
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Drinking straw
2 straw
30 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
String or twine
4 ft
60 ft
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Metal washer (test weight)
6 washer
90 washer
buy once, reuse
Plastic cup
1 cup
15 cup
consumed
Materials draw $0.94 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
String winds up crooked and jams the wheel. Add a cardboard flange either side of the spool.
Car lifts its front wheels instead of pulling. Move the string anchor lower, or add weight over the front axle.
Pacing
Running fast: Run the spool A/B test and write both numbers on the board.
Running behind: Skip the vehicle. Wind the string onto a spool on a fixed axle and pull a load along the table.
Spec · everyone reaches this
Travels 8 feet on one balloon.
Pro Spec · opt in, never assigned by grade
Land inside a 2 foot target zone 8 feet away, twice in a row.
Why this Pro Spec is reachable in 40 minutes
Two-stage balloon release is a genuinely hard mechanism. Hitting a target zone is the same skill (alignment and control) and it is achieved by truing the axles, which is exactly the lesson from 2A.
Before the session · guide prep
Cut 60 cardboard wheels (see 2A). 25 minutes.
Blow up one balloon and release it in the room the moment builders sit down. Say nothing.
Tape a start line and a 2 foot target zone 8 feet out.
Guided Bench · The Straw Rocket Car
Say each step, wait, say the next. Do not build it for them.
Build the straw axle car first.
Tape a straw pointing straight back off the rear.
Rubber band a balloon over the end of the straw.
Blow through the straw to inflate.
Pinch, place, release.
Show them first · pick one, not all three
Blow up a balloon and let it go in the room. This works every single time.
Search: balloon car race. Show one 30 second clip.
Show a rocket nozzle diagram and ask why it narrows.
Test Bench
Start line, tape measure, three runs, best counts.
Core skill
Thrust, mass, nozzle geometry
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Drinking straw
3 straw
45 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Balloon
2 balloon
30 balloon
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Rubber band
2 band
30 band
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.51 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Balloon deflates instantly with no push. The straw is too wide, or there is a leak at the neck. Rubber band the neck tighter.
Car spins in place. Too heavy at the back. Move the balloon forward or lighten the body.
Pacing
Running fast: Take the target Pro Spec, or try two straws at different angles.
Running behind: Tape the balloon straw to a flat cardboard sled with no wheels. It still slides and still measures.
03
Structures
Arc I
Shop Meeting question
Is it better to make something strong or make something light?
Spec · everyone reaches this
Holds 5 textbooks at center span.
Pro Spec · opt in, never assigned by grade
Half the bridge is unsupported for 8 inches and still holds 2 books.
Why this Pro Spec is reachable in 40 minutes
A true cantilever is a real engineering problem, but 12 inches unsupported in cardboard is a stretch inside 40 minutes. Eight inches and two books is achievable and it still forces them to think about counterweight.
Before the session · guide prep
Pre-fold 10 triangle box beams so Guided Bench has one to copy and one to build. 15 minutes.
Set the two tables exactly 24 inches apart and tape the floor so nobody moves them.
Stack the test books beside the gap where everyone can see them.
Guided Bench · The Box Beam Bridge
Say each step, wait, say the next. Do not build it for them.
Cut two long strips about 30 inches.
Fold each into a long triangle tube and tape it shut.
Tape the two tubes side by side with 4 inch spacers between them.
Tape a flat deck across the top.
Test with one book, then add.
Show them first · pick one, not all three
Hold a flat strip out flat, then fold it into a tube and hold it out again.
Search: truss bridge types. One image, then find the triangles together.
Draw an I-beam cross section on the board and ask where the material went.
Test Bench
Books added one at a time, counted out loud, until it goes.
Core skill
Beams, trusses, tension versus compression
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.24 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Bridge sags in the middle before any books go on. The deck is flat cardboard with no beam under it. Add a folded beam.
Beams splay apart sideways under load. Add cross spacers between them, at least three.
Pacing
Running fast: Take the cantilever Pro Spec, or keep loading past 5 books and post the number.
Running behind: Shorten the span to 18 inches. Same lesson, less material.
Spec · everyone reaches this
A builder gets in and it stands on its own.
Pro Spec · opt in, never assigned by grade
Built from at least 6 identical panels traced from one template you made.
Why this Pro Spec is reachable in 40 minutes
Designing a geodesic dome in 40 minutes is a college project. Making one template and tracing it six times teaches the actual idea (modularity) and it is genuinely faster than freehanding six panels, which is a satisfying thing to discover.
Before the session · guide prep
Source 15 to 20 large boxes. Start collecting two weeks out. This session lives or dies on box supply.
Cut two large triangles and two rectangles as the Guided Bench starter set. 10 minutes.
Clear real floor space. This build needs room.
Guided Bench · The Triangle Tent
Say each step, wait, say the next. Do not build it for them.
Cut two large triangles the same size.
Cut two long rectangles for the sides.
Tape the rectangles to the triangles to form an A shape.
Tape a long strip along the ridge.
Cut a door flap in one triangle.
Show them first · pick one, not all three
Squeeze an egg end to end (over a bowl) and let them try to break it.
Search: geodesic dome cardboard. Show the repeating panel.
Pop up a real camping tent in 30 seconds and take it down.
Test Bench
Builder gets in, guide counts to 20, then gently pushes one wall.
Core skill
Modularity, curved surfaces from flat stock
Supplies
Item
Per builder
For 15
Large appliance-size box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Duct tape
0.07 roll
1.1 roll
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.54 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Walls fold in as soon as someone gets inside. There is no ridge piece. Tape a strip along the top seam.
Nothing stands because every joint is a single tape strip. Tape both sides of every joint. Always.
Pacing
Running fast: Take the 6-identical-panel Pro Spec, or add a window and a working door flap.
Running behind: Build it to fit a stuffed animal instead of a person. Same structure, quarter the material.
Spec · everyone reaches this
Holds 15 pounds and does not sag.
Pro Spec · opt in, never assigned by grade
Fits an assigned wall space to within half an inch, measured.
Before the session · guide prep
Measure the actual wall or shelf space and write the target dimensions on the board before anyone arrives.
Pre-cut 25 identical rectangles for the layered shelf demo. 15 minutes.
Have the real supplies that will go on the shelf sitting on the floor.
Guided Bench · The Layered Shelf
Say each step, wait, say the next. Do not build it for them.
Cut five identical rectangles.
Glue them into a stack, turning the corrugation direction 90 degrees each layer.
Cut two matching end pieces.
Cut slots in the ends and slide the shelf in.
Load it up.
Show them first · pick one, not all three
Peel a piece of corrugated cardboard apart and show the flutes inside.
Show a piece of plywood edge-on and count the layers.
Search: cardboard furniture design. Pick the least crafty photos.
Test Bench
Loaded with actual supplies and left loaded for a week. Failures show up publicly.
Core skill
Measuring to a spec, load layering, permanence
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
6 sheet
90 sheet
free / donated
Hot glue stick
3 stick
45 stick
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Duct tape
0.05 roll
0.8 roll
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.53 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Shelf bows under load. Not enough layers, or the flutes all run the same way. Alternate direction every layer.
Ends split where the shelf slots in. Double the end panels before cutting the slot.
Pacing
Running fast: Take the half-inch tolerance Pro Spec and actually measure it with a tape in front of everyone.
Running behind: Build a 6 inch wide shelf instead of a full span. It still gets installed.
04
Launch
Arc I
Shop Meeting question
If your build worked the first time, did you learn anything?
Spec · everyone reaches this
Hits a 2 foot target zone from 8 feet.
Pro Spec · opt in, never assigned by grade
Three shots in a row land inside an 18 inch circle.
Why this Pro Spec is reachable in 40 minutes
A 12 inch circle from 8 feet is tighter than most adult-built cardboard catapults manage. Eighteen inches keeps the repeatability lesson and makes it winnable.
Before the session · guide prep
Build one spoon-arm catapult and leave it cocked on the table. 15 minutes.
Pre-punch pivot holes in 10 upright pairs so Guided Bench is not fighting cardboard with a skewer. 10 minutes.
Tape target circles on the floor at 18 and 24 inches, 8 feet from the firing line.
Decide the projectile in advance and use only that one: mini marshmallows or pom poms. Never anything hard.
Guided Bench · The Spoon-Arm Catapult
Say each step, wait, say the next. Do not build it for them.
Build a square base from four cardboard strips.
Tape two uprights in the middle with a skewer across as a pivot.
Tape a long arm to the skewer with a small cup on the end.
Loop a rubber band from the arm down to the front of the base.
Pull back and release.
Move the rubber band anchor to change the range.
Show them first · pick one, not all three
Flick a mini marshmallow off a spoon. Then flick it off a longer spoon.
Search: trebuchet slow motion. Watch the release.
Set and spring a mousetrap (guide only) and ask where the energy was hiding.
Test Bench
Target zones taped on the floor. Three shots each, scored aloud.
Core skill
Stored energy, lever arms, release timing
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Wooden skewer
3 skewer
45 skewer
consumed
Rubber band
4 band
60 band
consumed
Brass fastener
4 fastener
60 fastener
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Plastic cup
1 cup
15 cup
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.52 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Every shot goes a different distance. They are pulling back by feel. Mark three pull positions on the base and use only those.
The whole catapult jumps backward when it fires. Weight the base, or have a builder hold it down. Both are legitimate fixes.
Pacing
Running fast: Take the 3-in-a-circle Pro Spec, or add an adjustable rubber band anchor with three labeled notches.
Running behind: Skip the frame. Rubber band a spoon-arm to the edge of a heavy book. It fires and it aims.
Spec · everyone reaches this
Knocks a cup down from 6 feet.
Pro Spec · opt in, never assigned by grade
Knock down one specific cup in a row of five spaced 6 inches apart, without knocking its neighbors.
Why this Pro Spec is reachable in 40 minutes
Vortex cannons are genuinely precise, so this one was already realistic. The addition is the 6 inch spacing so the target is achievable and the test is unambiguous.
Before the session · guide prep
Build one bucket cannon and knock a cup over with it as builders walk in. 15 minutes.
Cut a 3 inch hole in 10 boxes ahead of time. A round hole in cardboard is slow work for a kid. 15 minutes.
Set cup rows at 4, 6, and 8 feet with tape marks.
Guided Bench · The Bucket Cannon
Say each step, wait, say the next. Do not build it for them.
Cut a round hole about 3 inches across in the bottom of a box.
Tape a trash bag or shower cap over the open end, loose not tight.
Tape all the edges airtight.
Pull the membrane back and snap it.
Aim at a cup, then at a candle.
Show them first · pick one, not all three
Guide blows out a candle from across the room with a prebuilt one. Do this first, explain nothing.
Search: air vortex cannon smoke. The smoke ring makes the invisible visible.
Ask them to describe the shape of the air that just hit them.
Test Bench
Cup rows at 4, 6, and 8 feet. Precision round after.
Core skill
Membranes, apertures, air pressure
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Trash bag or shower cap
1 piece
15 piece
consumed
Duct tape
0.07 roll
1.1 roll
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Plastic cup
3 cup
45 cup
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.67 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Nothing comes out. Air is leaking around the box seams. Tape every seam, inside and out.
Membrane is stretched drum tight and barely moves. It should be loose with slack in it.
Pacing
Running fast: Take the precision Pro Spec, or try a smaller hole and compare range.
Running behind: Use a paper cup with the bottom cut out and a balloon over the wide end. Works at 2 feet, builds in 8 minutes.
Spec · everyone reaches this
15 feet of controlled flight.
Pro Spec · opt in, never assigned by grade
Fly through a hoop 6 feet away, then do it again.
Why this Pro Spec is reachable in 40 minutes
Ten feet through a hoop is a much harder aiming problem than it sounds with a cardboard glider. Six feet twice keeps the repeatability lesson and is reachable in the session.
Before the session · guide prep
Cut 20 glider bodies and 40 wings from chipboard using one template. 20 minutes. This is the highest-leverage prep on the list.
Fly one badly, then trim it and fly it well, in front of them. Explain nothing.
Hang a hula hoop from a chair back at 6 feet.
Guided Bench · The Chipboard Dart
Say each step, wait, say the next. Do not build it for them.
Cut a long thin body from cereal box card.
Cut two wings and slot them into the body.
Cut a tail fin and slot it in.
Tape a paper clip to the nose.
Notch the tail and launch it off a rubber band hooked to a stick.
If it dives, bend the back edges of the wing up.
Show them first · pick one, not all three
Throw a paper airplane badly. Then trim it and throw it well. Say nothing in between.
Search: balsa glider flight. Watch how flat it stays.
Show a soaring bird clip and point at the wings not flapping.
Test Bench
Distance line on the floor, then the hoop round.
Core skill
Lift, center of gravity, trim
Supplies
Item
Per builder
For 15
Chipboard (cereal box panel)
3 panel
45 panel
free / donated
Cardstock sheet
2 sheet
30 sheet
consumed
Paper clip
3 clip
45 clip
consumed
Rubber band
2 band
30 band
consumed
Masking tape
0.03 roll
0.4 roll
consumed
Wooden skewer
1 skewer
15 skewer
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.23 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Dives straight into the floor. Nose is too heavy or the tail edges are flat. Bend the back edges of the wings up slightly.
Flips over backward. Too much bend, or not enough nose weight. Add one paper clip at a time.
Pacing
Running fast: Take the hoop Pro Spec, or add a second wing and compare glide.
Running behind: Build the body and one wing pair only. Throw by hand instead of building the launcher.
05
Play
Arc I
Shop Meeting question
Would you rather build one great thing or five okay things?
Spec · everyone reaches this
Two people play a full game without it breaking.
Pro Spec · opt in, never assigned by grade
Either a working score tracker or an automatic ball return. One, not both.
Why this Pro Spec is reachable in 40 minutes
The original asked for two independent subsystems on top of a working game. Either one alone is a real stretch goal inside the same 40 minutes.
Before the session · guide prep
Punch skewer holes through 10 shallow boxes ahead of time, evenly spaced and lined up on both sides. This alignment is fiddly and eats a whole session if learners do it cold. 20 minutes.
Build one box foosball and leave it out with a ball in it.
Decide the tournament bracket format before the session so the last 12 minutes run themselves.
Guided Bench · The Box Foosball
Say each step, wait, say the next. Do not build it for them.
Take a shallow box.
Cut a goal notch in each short end.
Punch holes for four skewers running across the box.
Slide the skewers through and tape clothespins or cardboard tabs on as players.
Drop a ping pong ball in and play.
Show them first · pick one, not all three
Bring one real foosball rod, or a photo of one, and look at how it's held.
Search: cardboard foosball table. Pick a rough looking one on purpose.
Ask what makes a game fun before you ask what makes it work.
Test Bench
Tournament. Tables that break are out of the tournament.
Core skill
Enclosures, rods and bearings, playtesting
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Wooden skewer
4 skewer
60 skewer
consumed
Binder clip
6 clip
90 clip
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Ping pong ball
1 ball
15 ball
buy once, reuse
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.25 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Rods bind and will not spin. Holes are not aligned across the box. Punch both sides at once with the box flat.
Ball gets stuck in the corners. Tape triangle fillets into all four corners.
Pacing
Running fast: Add the score tracker (a sliding cardstock strip with numbers) or the return channel.
Running behind: Two rods instead of four. It is still a real game.
Spec · everyone reaches this
Ball launches, hits three scoring features, and returns to the launcher.
Pro Spec · opt in, never assigned by grade
One player-controlled flipper: a lever on a brass fastener with a rubber band pulling it back.
Why this Pro Spec is reachable in 40 minutes
Two working flippers in cardboard inside 40 minutes is not realistic. One flipper is, and the mechanism (pivot plus return spring) is the entire lesson.
Before the session · guide prep
Build one tilt table with a working flipper. Builders need to see that a cardboard flipper is possible. 25 minutes.
Pre-punch flipper pivot holes in 15 base boards. 10 minutes.
Cut 15 launch channels from folded strips. 10 minutes.
Guided Bench · The Tilt Table
Say each step, wait, say the next. Do not build it for them.
Take a box lid and prop the far end up 2 inches.
Tape a channel down one side for the launch lane.
Rubber band a cardboard plunger at the bottom of the lane.
Tape bottle caps and folded card triangles down as bumpers.
Cut scoring holes and label them.
Show them first · pick one, not all three
Roll a marble at a bottle cap on the table. Then at a folded triangle. Compare.
Search: cardboard pinball machine build.
Show a real pinball table video with the sound on.
Test Bench
Every builder plays three other tables and scores them on fun, not looks.
Core skill
Inclines, levers, rebound geometry
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Brass fastener
4 fastener
60 fastener
consumed
Rubber band
4 band
60 band
consumed
Bottle cap
6 cap
90 cap
free / donated
Marble
2 marble
30 marble
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.65 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Marble rolls straight down the middle and nothing happens. Not enough obstacles near the top. Add bumpers in the first third.
Flipper flops and will not return. The rubber band is anchored too close to the pivot. Move the anchor further out.
Pacing
Running fast: Take the flipper Pro Spec, or add a second scoring level.
Running behind: No flipper. A plunger, bumpers, and scoring holes is a complete game.
Spec · everyone reaches this
Solvable in under 60 seconds by someone who did not build it.
Pro Spec · opt in, never assigned by grade
Mounted in a frame with two handles so you can tilt it without touching the board.
Why this Pro Spec is reachable in 40 minutes
A true two-axis gimbal needs two nested pivoting frames and is a multi-session build. A single frame with handles gets the same control idea in about 8 minutes.
Before the session · guide prep
Cut 15 base boards and pre-cut a bag of 1 inch wall strips. Strip cutting is what eats this session. 20 minutes.
Build one strip maze and let builders play it while you talk.
Have a stopwatch at the Test Bench from minute one.
Guided Bench · The Strip Maze
Say each step, wait, say the next. Do not build it for them.
Cut a flat base about 12 by 12.
Cut long strips 1 inch tall.
Glue the strips on edge to make a path.
Punch three holes as traps.
Tape a rim around the whole outside edge.
Drop a marble in and play.
Show them first · pick one, not all three
Bring a real labyrinth toy if you can find one. Let them fail at it.
Hand out a paper maze first and ask what makes it hard.
Search: labyrinth marble maze game.
Test Bench
Swap boards and time each other. A maze nobody can solve fails.
Core skill
Precision layout, pivots, difficulty tuning
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Hot glue stick
2.5 stick
37.5 stick
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Marble
2 marble
30 marble
buy once, reuse
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.50 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Walls fall off when tilted. Glued to the face instead of on edge with a bead of glue along the whole base.
Maze is impossible. Builder designed it for themselves. Make them watch someone else attempt it at minute 25.
Pacing
Running fast: Take the frame-and-handles Pro Spec, or add a second marble that must not fall.
Running behind: Six walls and one trap hole. Test it, then add more.
Arc II
Mechanism
Sessions 6 to 10
Energy, motion, and force. Every build here is a mechanism a robot needs.
Handoff
Phase 2: Five standing jobs go live, rotating weekly, held by Certified Builders.
Note
This is the arc that hooks 5th to 8th graders and makes the robotics connection concrete.
06
Stored Energy
Entry pointArc II
Shop Meeting question
When is it time to stop improving something?
Spec · everyone reaches this
Runs for 5 seconds under its own stored power.
Pro Spec · opt in, never assigned by grade
Stops within one car length of a marked line, two tries out of three.
Why this Pro Spec is reachable in 40 minutes
Six inches on a wind-up car is a coin flip. One car length, two out of three, is a control problem they can actually solve by counting winds.
Before the session · guide prep
Cut 60 cardboard wheels if the club has not already banked a supply. 25 minutes.
Build one rubber band racer and wind it in front of them.
Tape a 10 foot lane with a finish line and a marked stopping zone.
Guided Bench · The Rubber Band Racer
Say each step, wait, say the next. Do not build it for them.
Build the straw axle car (session 2).
Hook a rubber band to the rear axle.
Stretch it forward and hook it on a bent paper clip taped to the front.
Roll the car backward to wind it up.
Set it down and let go.
Show them first · pick one, not all three
Take a wind-up toy apart in front of them. Do not narrate.
Wind a rubber band around a pencil and let it spin on the table.
Search: rubber band powered car.
Test Bench
Wind, set down, hands off. Distance measured, then the stopping accuracy round.
Core skill
Energy storage, winding ratios
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Drinking straw
2 straw
30 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Rubber band
4 band
60 band
consumed
Paper clip
2 clip
30 clip
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.39 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Rubber band unwinds instantly with no drive. It is slipping on a smooth axle. Add a notch or a blob of glue for it to grip.
Car goes backward. The band is wound the wrong way. Roll the car the other direction to wind it.
Pacing
Running fast: Take the stopping-line Pro Spec. The trick is counting winds, and letting them discover that is the point.
Running behind: Wind-up spool on a fixed axle pulling a load along the table. No vehicle needed.
Spec · everyone reaches this
Launches 6 feet.
Pro Spec · opt in, never assigned by grade
Adjustable power with three repeatable, labeled settings.
Before the session · guide prep
Roll and tape 15 launch tubes ahead of time, sized to a ping pong ball. 20 minutes.
Cut the slot in each tube. Cutting a straight slot in a rolled tube is hard for kids and it is the failure point. 15 minutes.
Set a distance lane with markers at 3, 6, and 9 feet.
Guided Bench · The Plunger Tube
Say each step, wait, say the next. Do not build it for them.
Roll a tube from cardboard, wide enough for a ping pong ball.
Cut a slot down one side about 4 inches long.
Make a plunger disc on a stick that slides inside the tube.
Run a rubber band from the stick, out through the slot, to the front of the tube.
Pull back, load a ball, release.
Show them first · pick one, not all three
Take apart a retractable pen and find the spring.
Search: pinball plunger mechanism.
Pull a stapler open and look at the spring pushing the staples forward.
Test Bench
Settings 1, 2, and 3 fired three times each. Consistency scored, not distance.
Core skill
Elastic potential energy, calibration
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Cardboard tube
1 tube
15 tube
free / donated
Wooden skewer
2 skewer
30 skewer
consumed
Rubber band
4 band
60 band
consumed
Ping pong ball
2 ball
30 ball
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.90 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Plunger jams halfway. Disc is too big or the tube is not round. Trim the disc, do not force it.
Ball dribbles out. Rubber band is too weak or the pull is too short. Double the band.
Pacing
Running fast: Take the three-setting Pro Spec: three notches cut in the slot, labeled 1, 2, 3.
Running behind: Skip the tube. A rubber band across a U-shaped channel launches a ball just fine.
Spec · everyone reaches this
Triggers a target reliably twice in a row.
Pro Spec · opt in, never assigned by grade
At least 3 seconds pass between your trigger and the target falling.
Why this Pro Spec is reachable in 40 minutes
A true timer mechanism is out of reach. A delay is not: a long shallow ramp, or a marble in a spiral, buys 3 to 5 seconds easily. Same concept, reachable in 40 minutes.
Before the session · guide prep
Build the marble trigger and run it three times in front of them so they see 'reliably' means something.
Cut 15 pivot flaps and pre-punch the pivot holes. 12 minutes.
Have 30 stacking cups on hand for targets.
Guided Bench · The Marble Trigger
Say each step, wait, say the next. Do not build it for them.
Build a ramp from a folded strip.
At the bottom, balance a cardboard flap on a pivot.
Roll a marble down so it tips the flap.
Tape a string from the flap to a stack of cups.
Test until the cups fall every single time.
Show them first · pick one, not all three
Set up 20 dominoes and knock them over. Then ask what the last domino could do.
Search: Rube Goldberg machine short clip.
Balance a ruler on a pencil and put a coin on one end.
Test Bench
Two consecutive successes or it does not count.
Core skill
Triggering, energy transfer, reliability. Seeds session 11.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Marble
3 marble
45 marble
buy once, reuse
String or twine
3 ft
45 ft
consumed
Brass fastener
3 fastener
45 fastener
consumed
Plastic cup
4 cup
60 cup
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.81 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Works once, then never again. Nothing marks where the pieces go. Trace around every piece on the base.
Marble jumps the ramp. Side rails, full length, every time.
Pacing
Running fast: Take the 3 second delay Pro Spec. Long shallow ramp is the easiest route.
Running behind: Two steps instead of three. Marble tips a flap, flap knocks a cup. Done.
07
Fluid Power
Arc II
Shop Meeting question
Is it cheating to use a better material than everyone else?
Spec · everyone reaches this
Two working joints, lifts a ping pong ball.
Pro Spec · opt in, never assigned by grade
Two joints plus a scoop, and it moves a ping pong ball from one marked square to another.
Why this Pro Spec is reachable in 40 minutes
Three joints plus a working gripper is four mechanisms in 40 minutes, plus water. Two joints and a scoop is genuinely hard and genuinely achievable. The one-joint version is already a win.
Before the session · guide prep
Pre-fill and pair every syringe set the night before, purge the air, and cap the ends. Air bubbles are what kills this session, and filling syringes takes 30 seconds each. 25 minutes.
Cut tubing to 12 inch lengths.
Build the one-joint lifter and have it lifting something when they arrive.
Put towels down. Genuinely. Put towels down.
Add a few drops of food coloring to the water so leaks are visible and the mechanism is easier to read.
Guided Bench · The One-Joint Lifter
Say each step, wait, say the next. Do not build it for them.
Cut two cardboard strips and join them with a brass fastener as a hinge.
Fill two syringes with water and connect them with tubing, no air bubbles.
Tape one syringe body to the lower arm and its plunger end to the upper arm.
Push the other syringe and watch the arm move.
Tape a small cup on the end.
Show them first · pick one, not all three
Cap a full water bottle and ask a learner to squish it. Then uncap it.
Search: hydraulic arm cardboard syringe.
Show an excavator arm clip and count the cylinders.
Test Bench
Timed pick-and-place course. Spills are part of it.
Core skill
Fluid power, joints, linkage geometry
Supplies
Item
Per builder
For 15
Syringe, 10cc
2 syringe
30 syringe
buy once, reuse
Vinyl tubing, 1/8 in
1 ft
15 ft
buy once, reuse
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Brass fastener
4 fastener
60 fastener
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Ping pong ball
1 ball
15 ball
buy once, reuse
Plastic cup
1 cup
15 cup
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $2.33 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Push one syringe and the other barely moves. Air in the line. Purge it: submerge both ends and refill.
Tubing pops off under pressure. Zip tie or tape the connection, and do not over-push.
Pacing
Running fast: Take the two-joint Pro Spec, or add a second axis so the arm swings as well as lifts.
Running behind: One joint, lifting a ping pong ball off a table. That is the whole concept, working.
Spec · everyone reaches this
Floats and glides 3 feet on a smooth floor.
Pro Spec · opt in, never assigned by grade
Carries a payload of 200 grams (about two glue sticks and a battery pack) and still glides 3 feet.
Why this Pro Spec is reachable in 40 minutes
Directional control on a balloon hovercraft is not a 40 minute problem. Payload is measurable, immediate, and forces real thinking about the air cushion.
Before the session · guide prep
Drill or punch a hole in 15 bottle caps ahead of time. This is a guide job, not a learner job. 15 minutes.
Find the smoothest floor in the building and test it yourself first. Carpet kills this session.
Have the kitchen scale at the Test Bench.
Guided Bench · The Disc Hovercraft
Say each step, wait, say the next. Do not build it for them.
Tape a bottle cap with a hole drilled in it to the center of a stiff cardboard disc.
Punch a matching hole through the disc.
Stretch a balloon over the cap.
Inflate through the cap, pinch, place, release.
Show them first · pick one, not all three
Slide a puck on a smooth floor, then on carpet. Ask what changed.
Turn on an air hockey table if the school has one, or show a clip.
Search: balloon hovercraft build.
Test Bench
Glide distance down a taped lane, then the loaded run.
Core skill
Air cushions, thrust, weight distribution
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Bottle cap
2 cap
30 cap
free / donated
Balloon
3 balloon
45 balloon
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Metal washer (test weight)
8 washer
120 washer
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.19 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Sits there and does nothing. Disc is too heavy or too rough. Use thin card, and make sure the underside is smooth.
Air escapes out one side and it spins. The cap is not centered. Re-center it.
Pacing
Running fast: Take the payload Pro Spec, or race two on a taped lane.
Running behind: Skip the disc. A balloon taped over a hole in a paper plate hovers.
Spec · everyone reaches this
Launches a foam projectile 15 feet.
Pro Spec · opt in, never assigned by grade
Adjustable angle on a protractor mount, plus recorded data: three angles, three distances.
Before the session · guide prep
Assemble 8 stomp launcher bases yourself: bottle, tubing, sealed joint. The seal is the whole build and it is a guide job. 30 minutes.
Roll 20 paper rocket tubes sized to the tubing, or cut a template so builders can roll their own fast.
Take this one outside or into a hallway. Test the range yourself first.
Tape distance markers every 5 feet up to 30.
Guided Bench · The Stomp Launcher
Say each step, wait, say the next. Do not build it for them.
Tape a length of tubing tightly into the neck of an empty 2L bottle, sealed.
Roll a paper tube that slides loosely over the free end of the tubing.
Tape one end of the paper tube shut and add three fins.
Set the bottle on the floor, aim, and stomp.
Show them first · pick one, not all three
Step on an empty capped water bottle and let it pop.
Search: stomp rocket launcher.
Pump a bike pump with a finger over the outlet and pass it around.
Test Bench
Three angles, three shots each, distances charted on the whiteboard as a group.
Core skill
Pressure, angles, data collection
Supplies
Item
Per builder
For 15
Empty 2L bottle
shared
1 bottle
free / donated
Vinyl tubing, 1/8 in
shared
2 ft
buy once, reuse
Sketch paper sheet
4 sheet
60 sheet
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Duct tape
shared
0 roll
consumed
Foam projectile
1 projectile
15 projectile
buy once, reuse
Materials draw $0.83 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
No launch, just a hiss. Leak at the bottle neck. Wrap and tape until it is airtight, then test again.
Rocket goes 3 feet and flops. Tube is too loose on the tubing, or the fins are too small. Snug fit, three fins.
Pacing
Running fast: Take the angle and data Pro Spec. Three angles, three shots, chart it on the board.
Running behind: Share 4 launchers as stations. Everyone builds a rocket, everyone gets three shots.
08
Gears and Cams
Arc II
Shop Meeting question
Is the best builder in the room the one with the best build?
Spec · everyone reaches this
One moving figure driven by a cam.
Pro Spec · opt in, never assigned by grade
Two or more figures on different cams moving at different rhythms from one crank.
Before the session · guide prep
Cut 40 cam discs from a template with the hole punched off center. This is the single thing that makes automata work in one session. 25 minutes.
Build one up-and-down box and leave it cranking on the table.
Pre-punch the skewer holes in 15 box shells. 15 minutes.
Guided Bench · The Up-and-Down Box
Say each step, wait, say the next. Do not build it for them.
Make an open cube from cardboard.
Punch holes in two opposite sides and slide a skewer through.
Glue an off-center cardboard circle (the cam) onto the skewer inside the box.
Cut a hole in the box top and rest a second skewer down onto the cam.
Tape a figure to the top of the vertical skewer.
Bend a crank handle onto the end of the first skewer.
Show them first · pick one, not all three
Open a music box and watch the pins hit the comb.
Search: cardboard automata cam mechanism.
Turn a bike upside down and watch the pedal crank go round.
Test Bench
Ten continuous crank turns without jamming. Everyone cranks everyone else's.
Core skill
Cams, followers, rotary to linear motion
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Wooden skewer
3 skewer
45 skewer
consumed
Drinking straw
2 straw
30 straw
consumed
Brass fastener
2 fastener
30 fastener
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.52 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Vertical rod falls off the cam or jams. It needs a guide hole at the top and a flat foot at the bottom. Tape a small disc to the bottom of the rod.
Crank is impossible to turn. Holes are too tight. Widen with a pencil, not by forcing.
Pacing
Running fast: Take the two-cam Pro Spec. Offset the second cam a half turn.
Running behind: One cam, one rod, one shape on top. Cranks and moves. Complete.
Spec · everyone reaches this
Three meshing gears that turn together.
Pro Spec · opt in, never assigned by grade
Hit an assigned ratio (4 turns of the small gear to 1 of the big) and prove it by counting out loud.
Before the session · guide prep
Print and cut gear templates in two sizes: 12 tooth and 24 tooth. Trace-and-cut by hand does not mesh. 30 minutes, and it is the difference between this working and not working.
Cut at least 3 gears per builder from the templates, or have templates ready for them to trace.
Build one three-gear train and turn it in front of them.
Guided Bench · The Three Gear Train
Say each step, wait, say the next. Do not build it for them.
Trace three cardboard circles, one big and two small.
Cut teeth by making even notches around each edge. Use the template.
Push a brass fastener through each center into a cardboard base.
Space them so the teeth mesh with a little room.
Turn the big one and watch the small ones spin faster.
Show them first · pick one, not all three
Bring a hand eggbeater. Let them turn it slowly and watch.
Search: cardboard gears mechanism.
Show a bike's gear cassette and ask which gear is for a hill.
Test Bench
Mark one tooth on each gear. Count turns out loud as a group.
Core skill
Gear ratios, tooth spacing, mechanical advantage. Direct robotics transfer.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Brass fastener
4 fastener
60 fastener
consumed
Masking tape
0.04 roll
0.6 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Plastic gear, assorted
2 gear
30 gear
buy once, reuse
Materials draw $1.18 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Teeth skip instead of meshing. Gears are too far apart or too close. Loosen the fasteners and slide until it turns smoothly.
Gears bind on the fastener. Do not tighten the fastener flat. Leave it loose enough to spin freely.
Pacing
Running fast: Take the ratio Pro Spec, or add a fourth gear and predict the direction before turning.
Running behind: Two gears. Meshing two gears and watching direction reverse is the core idea.
Spec · everyone reaches this
Takes at least 10 seconds.
Pro Spec · opt in, never assigned by grade
At least 20 seconds, with three runs all within 5 seconds of each other.
Why this Pro Spec is reachable in 40 minutes
Hitting exactly 30 seconds plus or minus 2 with a rolling marble is a precision problem well beyond one session. Consistency within 5 seconds is a real, reachable target that teaches the same thing.
Before the session · guide prep
Build a switchback and time it in front of them. Say the number out loud.
Pre-cut a bag of angled strips at a consistent shallow angle. 15 minutes.
Tape three tall backing panels to the wall as shared build surfaces if space is tight.
Stopwatches at the Test Bench, one per three builders.
Guided Bench · The Switchback
Say each step, wait, say the next. Do not build it for them.
Tape a tall cardboard back panel upright.
Tape angled strips across it, alternating direction, about 3 inches apart.
Leave a gap at the end of each strip for the marble to drop through.
Add walls so the marble stays on.
Time it, then add more switchbacks to slow it down.
Show them first · pick one, not all three
Turn over an hourglass or a sand timer and just let it run while you talk.
Search: marble run slowest possible.
Drop a marble down a peg board and watch it bounce.
Test Bench
Stopwatch, three runs, average taken. Closest to target wins.
Core skill
Escapements, timing, controlled descent
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Hot glue stick
2.5 stick
37.5 stick
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Marble
3 marble
45 marble
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.54 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Marble flies off the end of every strip. Angle is too steep. Shallower, and add an end wall.
Marble stalls and stops. Angle is too shallow. There is a narrow band that works, and finding it is the lesson.
Pacing
Running fast: Take the 20 second consistency Pro Spec, or add a second marble that must not catch the first.
Running behind: Three switchbacks and a timed run. Post the number.
09
Circuits
Arc II
Shop Meeting question
Who owns an idea in this shop?
Spec · everyone reaches this
One LED lights reliably with a switch.
Pro Spec · opt in, never assigned by grade
Two LEDs wired in parallel on one switch, and it still lights when someone else operates it.
Why this Pro Spec is reachable in 40 minutes
Three LEDs and two independent switches means routing four separate copper tape paths without crossing, which is fiddly enough that most builders will not finish. Two in parallel teaches parallel circuits and finishes.
Before the session · guide prep
Make one light-up card yourself and test that your specific LEDs light off a single coin cell. Some blue and white LEDs will not. Test before you buy in bulk.
Pre-cut copper tape into 6 inch strips. Cutting copper tape off a roll is slow and it sticks to everything. 15 minutes.
Fold 30 cards ahead of time.
Draw the circuit path on the board as a loop, and leave it up all session.
Guided Bench · The Light-Up Card
Say each step, wait, say the next. Do not build it for them.
Fold a card.
Lay copper tape in a path from the battery spot to the LED spot and back. Never cut the tape at a corner, fold it.
Tape the LED legs down, long leg to the positive path.
Set the coin cell on its pad.
Fold the card so a flap presses the battery down. That flap is your switch.
Show them first · pick one, not all three
Unscrew a light switch plate and look behind it.
Search: paper circuit LED card.
Hold up a string of holiday lights with one bulb pulled out.
Test Bench
Hand your build to another builder. If they cannot make it light, it fails.
Core skill
Circuits, series versus parallel, switches. Robotics on-ramp.
Supplies
Item
Per builder
For 15
Cardstock sheet
2 sheet
30 sheet
consumed
Copper tape
1.5 ft
22.5 ft
consumed
CR2032 coin cell
1 cell
15 cell
consumed
LED, 5mm
2 LED
30 LED
consumed
Masking tape
0.03 roll
0.4 roll
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.10 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
LED does not light. Nine times out of ten it is backwards. Flip it. The long leg is positive.
Copper tape was cut at a corner and the circuit is broken. Never cut at a corner. Fold the tape over on itself.
Pacing
Running fast: Take the two-LED parallel Pro Spec, or add a second switch on a separate flap.
Running behind: One LED, one battery, no switch. Press the battery to complete the circuit by hand. That is a circuit.
Spec · everyone reaches this
Buzzes on contact, resets, and is playable.
Pro Spec · opt in, never assigned by grade
A difficulty setting: a second, narrower loop the player can swap to.
Why this Pro Spec is reachable in 40 minutes
Scoring plus strike counting is two subsystems on top of the circuit. A second loop is a 2 minute addition that changes the game meaningfully.
Before the session · guide prep
Bend 15 wire courses yourself. Bending 16 gauge wire is hard on small hands and it is the least educational part of the build. 25 minutes.
Build one and let people play it before the Shop Meeting starts.
Test your buzzers with your battery packs beforehand. Voltage mismatches are silent failures.
Guided Bench · The Loop Run
Say each step, wait, say the next. Do not build it for them.
Bend a stiff wire into a wavy course.
Push both ends into a cardboard base.
Make a handle: a loop of wire on a stick.
Wire the battery, buzzer, wire course, and loop into one circle using alligator clips.
Materials draw $5.36 per builder (high cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Buzzer sounds constantly. The loop is touching the course at the start, or a lead is shorted. Separate and re-check.
Nothing happens on contact. A connection is loose. Work around the circle one clip at a time.
Pacing
Running fast: Take the second-loop Pro Spec, or wire an LED in as well as the buzzer.
Running behind: Use an LED instead of a buzzer. Simpler circuit, same game, much quieter room.
Spec · everyone reaches this
Moves on its own and leaves marks.
Pro Spec · opt in, never assigned by grade
Make it reliably travel in circles rather than wandering. Prove it three times.
Why this Pro Spec is reachable in 40 minutes
Predictable straight-line travel from a vibration bot is close to impossible. Circles are the natural behavior when the motor is off center, so this Pro Spec is achievable and it teaches center of mass directly.
Before the session · guide prep
Build one cup bot and let it draw on a big sheet while builders arrive.
Pre-strip and tin the motor wires, or use motors with leads already attached. Stripping tiny wires is a guide job. 20 minutes.
Tape a large roll of paper to the floor before anyone arrives.
Test one motor and battery pairing so you know it runs.
Guided Bench · The Cup Bot
Say each step, wait, say the next. Do not build it for them.
Tape three markers to a cup, points down, as legs.
Tape a pager motor to the top rim.
Tape a battery holder next to it.
Connect the two wires.
Set it on paper and let it draw.
Move the motor off center to change the path.
Show them first · pick one, not all three
Put a phone on vibrate on a hard table and watch it walk.
Search: bristlebot vibrating robot.
Talk about an unbalanced washing machine walking across a laundry room.
Test Bench
Big paper on the floor. Everyone runs at once. Predictability round after.
Core skill
Motors, vibration, center of mass. Robotics on-ramp.
Supplies
Item
Per builder
For 15
Vibration / pager motor
1 motor
15 motor
buy once, reuse
AA battery holder
1 holder
15 holder
buy once, reuse
AA battery
2 battery
30 battery
consumed
Plastic cup
1 cup
15 cup
consumed
Washable marker
3 marker
45 marker
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $5.16 per builder (high cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Does not move at all. Battery is in backwards, or a wire came loose. Check both before anything else.
Tips over immediately. Marker legs are uneven. Stand it on a flat table and adjust until all three touch.
Pacing
Running fast: Take the circles Pro Spec, or race two bots across a taped lane.
Running behind: Tape the motor to a paper plate with three markers. Two minutes to build, still draws.
10
Linkages and the Handoff
Arc II
Shop Meeting question
Is it harder to build something or to teach someone to build it?
Spec · everyone reaches this
Picks up a cup from 2 feet away.
Pro Spec · opt in, never assigned by grade
Picks up a ping pong ball resting on a bottle cap from 3 feet away.
Why this Pro Spec is reachable in 40 minutes
An egg is unforgiving and the cleanup is real. A ball on a cap is the same precision and grip-control problem with none of the mess, and it can be attempted repeatedly.
Before the session · guide prep
Pre-cut 150 identical strips and pre-punch all three holes using a template. This is the whole session. Without it, nobody finishes. 35 minutes, and it is worth every minute.
Build one scissor reacher and pick something up with it when they walk in.
Bring a trash picker tool if you can find one.
Guided Bench · The Scissor Reacher
Say each step, wait, say the next. Do not build it for them.
Cut eight identical cardboard strips.
Punch a hole at each end and one in the middle of every strip.
Join them into X pairs with brass fasteners, then chain the pairs together.
Push and pull the base pair and watch it extend.
Tape two hooked flaps on the far end as jaws.
Show them first · pick one, not all three
Bring a trash picker tool. Let them use it before you explain anything.
Search: pantograph grabber mechanism.
Open and close an accordion baby gate.
Test Bench
Pick-and-place course, then the egg round.
Core skill
Linkages, grip force, scissor mechanisms. This is a robot end effector.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Brass fastener
12 fastener
180 fastener
consumed
Masking tape
0.04 roll
0.6 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Ping pong ball
1 ball
15 ball
buy once, reuse
Bottle cap
2 cap
30 cap
free / donated
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.74 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Extends once then binds. Fasteners are too tight. Every single one has to stay loose.
Strips bend instead of pivoting. Cardboard is too thin. Double it, or use chipboard laminated in two layers.
Pacing
Running fast: Take the ball-on-a-cap Pro Spec, or add a working jaw that closes as it extends.
Running behind: Four strips instead of eight. It extends half as far and teaches the same thing.
Spec · everyone reaches this
Takes three steps under a crank or a pull.
Pro Spec · opt in, never assigned by grade
Takes six steps without falling over.
Why this Pro Spec is reachable in 40 minutes
Two feet in a straight line requires gait symmetry that is a serious mechanism problem. Six steps upright is hard, satisfying, and reachable.
Before the session · guide prep
Build one waddler and get it walking. If you cannot get it walking in 30 minutes, run a different option this week. This is the hardest build in the program and that is stated deliberately.
Pre-punch the body pivot holes on 15 body panels. 15 minutes.
Cut 60 leg strips from one template. 20 minutes.
Guided Bench · The Two-Leg Waddler
Say each step, wait, say the next. Do not build it for them.
Cut a body panel.
Cut four leg strips.
Fasten two legs to a crank skewer through the body, offset half a turn from each other.
Fasten the other two legs to a fixed pivot higher up.
Turn the crank slowly and adjust leg length until it steps.
Show them first · pick one, not all three
Search: Theo Jansen strandbeest. This one sells itself.
Walk across the room in slow motion and have them describe your legs.
Wind up a walking toy and set it on the table.
Test Bench
Steps counted out loud. Distance measured.
Core skill
Four-bar linkages, gait, balance. Genuinely hard, which older builders like.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Brass fastener
8 fastener
120 fastener
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Drinking straw
1 straw
15 straw
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.56 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Legs swing but the body never lifts. Legs are the same length. The crank leg needs to be shorter than the fixed pivot leg.
It falls sideways every time. Too narrow. Widen the stance or add a third contact point at the back.
Pacing
Running fast: Take the six-step Pro Spec, or add a second pair of legs.
Running behind: Two legs on one crank, pulled along by hand. It steps. That counts.
Spec · everyone reaches this
The teacher's build works. The learner's build works.
Pro Spec · opt in, never assigned by grade
Teach without touching your student's build. Voice only.
Before the session · guide prep
Print the Shop Book Arc II pages so builders can shop for what they want to learn.
Stage the materials for all five Arc II builds in labeled bins.
Rehearse the bad lesson and the good lesson. The bad one has to be genuinely bad: grab the thing and do it for them.
Guided Bench · The Teaching Clinic
Say each step, wait, say the next. Do not build it for them.
Guide runs a teaching clinic instead of a build.
How to ask 'what have you tried' instead of showing.
How to keep your hands down.
How to check whether they actually understood.
Then the pairs go and build.
Show them first · pick one, not all three
Model a bad lesson: grab the thing and do it for them. Then model a good one.
Open the Shop Book to every Arc II page and let them shop for what they want to learn.
Ask the room who taught them something this year, and how.
Test Bench
Both builds tested side by side. The teacher is scored on the student's build, not their own.
Core skill
All of Arc II, plus the actual point. This is the Lead Builder audition.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Brass fastener
4 fastener
60 fastener
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Rubber band
3 band
45 band
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.44 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
The teacher just builds it for their student. Physically move the teacher's chair back one foot. It works.
The pair picks something neither can finish. Guide vetoes the pairing at minute 5, not minute 30.
Pacing
Running fast: Teach a second person, or take the hands-off Pro Spec.
Running behind: Teach one step of a build rather than a whole build.
Arc III
Systems
Sessions 11 to 15
Bigger, collaborative, multi-part builds. The shop stops being a room full of separate projects.
Handoff
Phase 3: A Guest Shop Lead runs the Shop Meeting and the Shop Talk from a prep card.
Note
Highest-value stretch in the program. Running a Shop Talk is the skill that makes sessions 16 to 25 survivable.
11
Chain Reaction
Entry pointArc III
Shop Meeting question
What do you owe someone who helped you?
Spec · everyone reaches this
The full room chain completes start to finish, once.
Pro Spec · opt in, never assigned by grade
Your segment has three energy transfers and one delay.
Before the session · guide prep
Decide the handoff standard before the session and write it on the board: a marble arriving at table height on the left. Teams negotiate everything else. Without a published standard this session collapses.
Cut 30 ramp strips and 60 dominoes ahead of time. 20 minutes.
Arrange tables in one continuous line before builders arrive.
Guided Bench · The Three-Step Segment
Say each step, wait, say the next. Do not build it for them.
Marble rolls down a ramp.
Marble knocks over a standing domino stack.
The falling stack tugs a string that releases the next marble.
Build exactly that.
Then walk it over and connect it to a neighbor's segment.
Show them first · pick one, not all three
Search: OK Go This Too Shall Pass. Play it once, no talking over it.
Run 30 real dominoes across the table.
Ask what happens if one team's segment fails. Let that sit.
Test Bench
One take, filmed. Then a second take. The negotiation over handoffs is the actual curriculum.
Core skill
Integration, interface standards, debugging under pressure
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Marble
4 marble
60 marble
buy once, reuse
Plastic cup
3 cup
45 cup
consumed
String or twine
4 ft
60 ft
consumed
Masking tape
0.09 roll
1.3 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Brass fastener
3 fastener
45 fastener
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.92 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Segments work alone but not connected. Nobody agreed a height. Stop the room at minute 20 and set one.
One team's failure blocks everyone. Build in a manual override: a builder may hand-start the next segment and the run still counts as a partial.
Pacing
Running fast: Take the three-transfer Pro Spec, or add a delay step.
Running behind: Two teams instead of eight segments. Connect two, film it, done.
Spec · everyone reaches this
It works once, on camera.
Pro Spec · opt in, never assigned by grade
It works twice in a row.
Before the session · guide prep
Build the last three feet of the machine yourself, including the target. Have it working before anyone arrives. 25 minutes.
Set the absolute deadline for connections at minute 30 so there are 10 minutes to film and reset.
Charge a phone or camera.
Guided Bench · The Finish Line
Say each step, wait, say the next. Do not build it for them.
Guide's group owns the last three feet of the machine and the target.
Build the ending first so there is always a finish line.
Make it reliable before anyone connects to it.
Test it 10 times alone.
Then hand the input end to the club.
Show them first · pick one, not all three
Watch a toaster pop. Slowly. On purpose.
Search: Rube Goldberg simple machine.
Show a vending machine spiral turning.
Test Bench
Filmed. Reset. Filmed again.
Core skill
Systems thinking, reliability, patience
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Marble
4 marble
60 marble
buy once, reuse
Plastic cup
3 cup
45 cup
consumed
String or twine
4 ft
60 ft
consumed
Masking tape
0.09 roll
1.3 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Popsicle stick
6 stick
90 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.94 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
It never completes and morale drops. Film a partial run at minute 32 regardless. A partial on camera beats nothing.
Everyone crowds one section. Assign zones on the floor with tape at the start.
Pacing
Running fast: Take the twice-in-a-row Pro Spec.
Running behind: Cut the machine to five steps and get those five perfect.
Spec · everyone reaches this
A marble travels the full wall.
Pro Spec · opt in, never assigned by grade
Design a module type nobody else built and have another builder install it successfully.
Before the session · guide prep
Cut 25 backing panels to exactly 12 by 12 inches. Identical size is the whole point and eyeballing it ruins the session. 25 minutes.
Mark the entry and exit points on every panel with a marker before handing them out. This is the spec, made physical.
Clear a wall and tape a grid on it.
Guided Bench · The Standard Chute
Say each step, wait, say the next. Do not build it for them.
Cut a 12 inch square backing panel. This is the module.
Fold a long strip into a U channel.
Tape the channel diagonally across the panel.
Marble must enter top left and exit bottom right. Every time.
That entry and exit rule is the spec everyone in the room follows.
Show them first · pick one, not all three
Hold up two modules and swap them. That swap is the whole idea.
Search: modular marble run wall.
Show a mail sorting chute or a coin sorter.
Test Bench
Marble dropped at the top. Every module that fails gets fixed by its builder in front of everyone.
Core skill
Standards, modularity, interchangeability
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Hot glue stick
2.5 stick
37.5 stick
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Marble
3 marble
45 marble
buy once, reuse
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.66 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Marble leaves a module and misses the next one. The exit point drifted. Check against the marked point, not by eye.
Modules will not stay on the wall. Use painter's tape in a full perimeter, not four corner tabs.
Pacing
Running fast: Take the new-module-type Pro Spec, or build two modules.
Running behind: One module, installed, marble passes through. Complete.
12
Shared Worlds
Arc III
Shop Meeting question
Should the shop have a leader?
Spec · everyone reaches this
Your building meets the grid spec and connects to a neighbor's.
Pro Spec · opt in, never assigned by grade
Your structure has a working mechanism: a door, an elevator, a drawbridge.
Before the session · guide prep
Cut 25 base plates to exactly 8 by 8 inches. Same reasoning as 11C. 25 minutes.
Tape the street grid on the floor before builders arrive so the city has a shape to grow into.
Build one grid building as the example, and deliberately build a second one that is the wrong size so the spec problem is visible.
Guided Bench · The Grid Building
Say each step, wait, say the next. Do not build it for them.
Cut a base exactly 8 inches square. No exceptions, this is the spec.
Build four walls that sit inside the base edge.
Cut a door on one side facing a street edge.
Add a flat roof.
Set it next to a neighbor's and check the streets line up.
Show them first · pick one, not all three
Put two Lego baseplates together and pull them apart. That is the whole lesson.
Pull up a city map and find the grid.
Search: cardboard city model.
Test Bench
The city gets assembled on the floor. Anything that does not fit gets fixed live.
Core skill
Shared standards, negotiation, zoning arguments that are genuinely Socratic
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Brass fastener
2 fastener
30 fastener
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.42 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Buildings do not line up on the street. Walls were built outside the base edge. Inside the edge, always.
Nobody wants their building at the edge of the city. Assign plots by drawing lots at minute 3.
Pacing
Running fast: Take the working-mechanism Pro Spec. A hinged door on brass fasteners is the easiest route.
Running behind: Base plate, four walls, roof, door. Complete building, meets spec.
Spec · everyone reaches this
A visitor learns the thing without a builder explaining it.
Pro Spec · opt in, never assigned by grade
The exhibit survives ten visitors operating it.
Before the session · guide prep
Build the pull-tab exhibit and let a learner try it cold before you decide it is clear.
Cut 25 panels with the window already cut out. Cutting a clean interior window is a guide job. 25 minutes.
Arrange for another studio to visit for the last 12 minutes. Confirm it the week before.
Guided Bench · The Pull-Tab Exhibit
Say each step, wait, say the next. Do not build it for them.
Cut a panel with a window in it.
Make a slider strip that passes behind the window.
Draw two states on the strip: before and after.
Add a pull tab.
Add one label of five words or fewer.
Show them first · pick one, not all three
Bring a pull-tab children's book and pull the tab.
Search: hands on science museum exhibit.
Ask them about the best museum thing they ever touched.
Test Bench
Invite another studio in. Builders stand behind their exhibit and say nothing.
Core skill
Design for a user, durability, instructions-free design
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Cardstock sheet
3 sheet
45 sheet
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Brass fastener
2 fastener
30 fastener
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.92 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Visitor does not know what to do. No affordance. Add an arrow and the word PULL.
Slider jams on the first pull. Track is too tight. Widen it by a finger width.
Pacing
Running fast: Take the ten-visitor durability Pro Spec, or add a second state to the slider.
Running behind: One panel, one slider, one label. That is a working exhibit.
Spec · everyone reaches this
At least one vehicle completes the course.
Pro Spec · opt in, never assigned by grade
Design an obstacle that at least half the vehicles fail and at least one passes.
Before the session · guide prep
Retrieve the session 2 cars from storage, or build 6 spares. If the cars are gone this option does not run.
Measure the widest car and write that number on the board. Every gate references it.
Cut 20 ramp strips and 20 gate panels. 20 minutes.
Guided Bench · The Ramp and Gate
Say each step, wait, say the next. Do not build it for them.
Fold a long strip into a ramp with side rails.
Prop it on a box.
Cut a doorway gate from a panel and stand it 12 inches past the ramp bottom.
Make the gate exactly 1 inch wider than the widest car.
Test with a car and adjust.
Show them first · pick one, not all three
Set up a Hot Wheels loop if you can borrow one.
Search: robotics competition field. Look at how the obstacles are built.
Ask what makes an obstacle fair versus impossible.
Test Bench
Every car from session 2 runs it. Obstacles that nothing passes get redesigned live.
Core skill
Course design, difficulty tuning. Rehearses building a robotics arena.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Masking tape
0.09 roll
1.3 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Duct tape
0.04 roll
0.6 roll
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.48 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Cars fly off the ramp. No side rails. Full length, every ramp.
Nothing passes any obstacle. Obstacles were designed without testing. Rule: you must run a car through your own obstacle before you add another.
Pacing
Running fast: Take the half-pass Pro Spec. Designing an obstacle that is exactly hard enough is genuinely difficult.
Running behind: One ramp and one gate per builder, connected into a single course.
13
Synthesis
Arc III
Shop Meeting question
What is the point of a plan if you are going to change it?
Spec · everyone reaches this
Your game includes at least one Arc II mechanism: cam, gear, circuit, linkage, or pneumatic.
Pro Spec · opt in, never assigned by grade
Two scoring zones that are physically separate, so the score is obvious without anyone judging it.
Why this Pro Spec is reachable in 40 minutes
Automatic scoring with a counter is beyond a session. Physically separated catch trays give you unambiguous scoring with no judge, which is the actual goal, and it is a 5 minute addition.
Before the session · guide prep
Print the session 1 arcade photos from the Shop Book and post them.
If builders are adding circuits, pre-cut copper tape strips (see 9A). 15 minutes.
Stage every Arc II material bin so builders can pick their mechanism without hunting.
Invite families or another studio for the last 15 minutes. Confirm a week out.
Guided Bench · The Lit-Up Skee-Ball
Say each step, wait, say the next. Do not build it for them.
Build the session 1 skee-ball ramp again.
Add a paper circuit behind the 50 point hole.
Lay the copper tape so a landing ball presses two contacts together.
LED lights when they score.
Test it twenty times before anyone plays.
Show them first · pick one, not all three
Open the Shop Book to the session 1 photos. Ask what they would do differently.
Search: cardboard arcade game mechanism.
Show a real arcade coin mech, or a photo of one.
Test Bench
Public arcade session. Invite a studio or families in.
Core skill
Synthesis. The year's midpoint proof and the natural build to show families.
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Ping pong ball
1 ball
15 ball
buy once, reuse
Marble
3 marble
45 marble
buy once, reuse
Brass fastener
4 fastener
60 fastener
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Copper tape
1 ft
15 ft
consumed
LED, 5mm
1 LED
15 LED
consumed
CR2032 coin cell
1 cell
15 cell
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.68 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Mechanism added but the game stopped being fun. Ask: would you play this? Fun first, mechanism second.
Circuit works on the bench but not in the game. Ball impact is breaking the contact. Reinforce the contact point with a card backing.
Pacing
Running fast: Take the two-zone Pro Spec, or add a light that fires on the high-score zone.
Running behind: Rebuild the session 1 game with one improvement. The comparison is the lesson.
Spec · everyone reaches this
Token in, one item out, reliably three times.
Pro Spec · opt in, never assigned by grade
Rejects a wrong-sized token.
Why this Pro Spec is reachable in 40 minutes
Two selectable items means two stacks, two slides, and a selector, which is a lot. Token rejection is a slot width, which is one cut and a genuinely satisfying piece of mechanical logic.
Before the session · guide prep
Build the single-drop mechanism and run it ten times. If it jams for you it will jam for them.
Cut 40 identical token discs and 20 slightly larger reject discs from cardboard. 20 minutes.
Cut 25 stack tubes sized to the discs. 15 minutes.
Guided Bench · The Single Drop
Say each step, wait, say the next. Do not build it for them.
Build a tall box with a stack tube inside holding cardboard discs.
Cut a slot at the bottom exactly one disc tall.
Make a slide that pushes one disc out and blocks the next one.
Tie the slide to a lever on the outside.
Pull the lever. One comes out.
Show them first · pick one, not all three
Bring a PEZ dispenser. Click it a few times.
Search: cardboard vending machine mechanism.
Ask how a gumball machine gives you exactly one.
Test Bench
Ten tokens in a row. Every jam is counted out loud.
Core skill
Sorting, gating, mechanical logic. Serious build.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
3 sheet
45 sheet
consumed
Brass fastener
3 fastener
45 fastener
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.55 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Two items come out at once. The slide is thicker than one disc. It must be exactly one disc tall.
Stack jams. Tube is too tight, or the discs are not uniform. Cut discs from a template.
Pacing
Running fast: Take the token rejection Pro Spec. A slot exactly one token wide does it.
Running behind: A gravity chute with a hand-operated gate. Still one item at a time.
Spec · everyone reaches this
Your rig produces the same result twice on the same object.
Pro Spec · opt in, never assigned by grade
Your rig measures something numerically instead of just pass or fail.
Before the session · guide prep
Bring the bathroom scale, the luggage scale, and a stopwatch to the front and use each one badly on purpose.
Cut 20 tube sections for drop rigs. 12 minutes.
Pick 5 identical test objects (all the same, so rigs can be compared) and set them aside.
Guided Bench · The Drop Rig
Say each step, wait, say the next. Do not build it for them.
Tape a tube upright to a wall at a marked height.
Mark the height on the wall in inches.
Tape a target square on the floor below.
Drop the object and record what happened.
Do it twice and compare.
Show them first · pick one, not all three
Put a bathroom scale on the table and press it. Ask what it is actually doing.
Search: drop test lab equipment.
Ask what would make a test unfair.
Test Bench
Two builders run the same object through your rig. Different results means the rig fails.
Core skill
Testing methodology, measurement, fairness. Makes the Test Bench itself learner-owned.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Cardboard tube
1 tube
15 tube
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
String or twine
3 ft
45 ft
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.40 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Two runs give different results and the builder blames the object. Ask what moved between runs. Usually the rig.
Rig measures nothing, just breaks things. Add a scale, a ruler, or a count. Pass or fail is the floor, not the goal.
Pacing
Running fast: Take the numeric measurement Pro Spec.
Running behind: A marked drop height and a target square is a legitimate rig.
14
Scale
Arc III
Shop Meeting question
What makes a rule worth following when nobody is watching?
Spec · everyone reaches this
It stands and it does the one thing it is supposed to do.
Pro Spec · opt in, never assigned by grade
Comes apart into transportable sections and reassembles in under 5 minutes.
Before the session · guide prep
Cut 60 panels at exactly 18 by 18 inches with slots at the same two positions. Use a jig. This is 45 minutes of prep and there is no way around it.
Decide what the club is building before the session and sketch it on the board. A whole-club build with no target wastes 40 minutes.
Clear the floor completely.
Guided Bench · The Panel and Slot System
Say each step, wait, say the next. Do not build it for them.
Cut identical 18 inch square panels.
Cut 3 inch slots at the same two spots on every panel edge.
Slide panels together at right angles.
Show that any panel fits any other panel.
The guided group becomes the panel factory for the whole club.
Show them first · pick one, not all three
Assemble a flat pack shelf, badly, in front of them.
Search: giant cardboard construction.
Show a shipping container and ask why they all match.
Test Bench
Built, then disassembled, then rebuilt against a timer.
Core skill
Scale, joinery, project management
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
6 sheet
90 sheet
free / donated
Duct tape
0.07 roll
1.1 roll
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.52 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Structure leans and then folds. No diagonal bracing. Panels alone are not enough at scale.
Builders work in isolation and nothing connects. Assign a lead at minute 5 to own the overall shape.
Pacing
Running fast: Take the disassembly Pro Spec and time the rebuild.
Running behind: Build half the intended structure and stand it up. Standing beats ambitious.
Spec · everyone reaches this
Wearable, moves with the wearer, and survives 5 minutes of walking around.
Pro Spec · opt in, never assigned by grade
An actuated element the wearer triggers: wings that open, a visor that lifts.
Before the session · guide prep
Build one articulated gauntlet and wear it around the room. Bend your wrist a lot.
Cut 100 curved strips in graduating widths from a template. 30 minutes and it is the whole build.
Pre-punch the overlap holes. 15 minutes.
Set up a short obstacle lap for the wear test.
Guided Bench · The Articulated Gauntlet
Say each step, wait, say the next. Do not build it for them.
Cut five curved strips, each slightly wider than the last.
Overlap them like roof shingles along a forearm.
Punch and fasten each overlap with a brass fastener, loose not tight.
Add a strip of cardstock or elastic underneath to hold it on.
Bend your wrist and check it still moves.
Show them first · pick one, not all three
Bring a cooked lobster tail or a photo of one. Bend it.
Search: cardboard cosplay armor articulation.
Show a knight's gauntlet photo and count the plates.
Test Bench
Wear it and complete an obstacle lap. Anything that falls off fails.
Core skill
Articulation, ergonomics, joints under load
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Brass fastener
14 fastener
210 fastener
consumed
Cardstock sheet
3 sheet
45 sheet
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
String or twine
3 ft
45 ft
consumed
Zip tie
4 tie
60 tie
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.02 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Plates lock up and will not bend. Fasteners are tight. Loose, every time, on every joint.
Falls off the moment they walk. No retention. Add a cardstock strap or elastic underneath.
Pacing
Running fast: Take the actuated Pro Spec. A string from a finger loop to a hinged plate is the easiest route.
Running behind: Three plates instead of five. It still articulates.
Spec · everyone reaches this
Runs for 30 seconds on one crank or one wind.
Pro Spec · opt in, never assigned by grade
Three distinct motions from one input.
Before the session · guide prep
Cut 60 cam discs from a template with off-center holes (see 8A). 25 minutes.
Build the three-cam flock and run it slowly in silence when they arrive.
Pre-punch skewer holes in 15 box shells. 15 minutes.
Guided Bench · The Flock
Say each step, wait, say the next. Do not build it for them.
Build the session 8 cam box.
Instead of one figure, mount three vertical skewers on three cams.
Offset each cam by a third of a turn.
Tape a shape on each skewer.
Crank slowly and watch the wave move.
Show them first · pick one, not all three
Hang a mobile over the table and set it spinning.
Search: kinetic sculpture wooden mechanism.
Ask whether a machine can be beautiful and useless at the same time.
Test Bench
Silent viewing. Everyone watches each one run. No talking during.
Core skill
All of Arc II at once, plus aesthetics as a real design constraint
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Wooden skewer
4 skewer
60 skewer
consumed
Drinking straw
3 straw
45 straw
consumed
Brass fastener
3 fastener
45 fastener
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
3 sheet
45 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.67 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Cranks stiffly and stalls. Too many cams on one shaft with too much friction. Straws as bearings at every hole.
All three shapes move identically. Cams are not offset. Rotate each one on the shaft before gluing.
Pacing
Running fast: Take the three-motion Pro Spec.
Running behind: Two cams. The offset is visible with two.
15
The Pivot
Arc III
Shop Meeting question
Is a build that broke during testing a success or a failure?
Second half of this session is the pitch workshop that launches the learner-led block. Every builder writes one Pitch Card.
Spec · everyone reaches this
Meets the dimensions the robotics team gives you.
Pro Spec · opt in, never assigned by grade
Includes a scoring element that moves or resets.
Before the session · guide prep
Get the robotics challenge dimensions in writing at least three weeks out. Without the spec this option does not run.
Print the spec, one copy per team, and read it aloud at Shop Meeting.
Cut large panels to rough size. 20 minutes.
Arrange for the robotics team to test it, ideally the same week.
Guided Bench · The Scoring Goal
Say each step, wait, say the next. Do not build it for them.
Build a three-sided box open at the front.
Cut the opening to the exact width the robotics team specified.
Add a ramped floor so scored objects roll to the back.
Add a hinged flap so the goal can be emptied.
Measure twice before cutting anything.
Show them first · pick one, not all three
Bring the robotics team's actual spec sheet and read it aloud.
Search: FIRST Lego League field setup.
Look up a regulation basketball hoop's dimensions and ask why they are exact.
Test Bench
The robotics team runs a robot through it and reports back.
Core skill
Building to someone else's spec. Client work.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
6 sheet
90 sheet
free / donated
Duct tape
0.09 roll
1.3 roll
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Brass fastener
4 fastener
60 fastener
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Painter's tape
0.05 roll
0.8 roll
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.98 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Built to a remembered number instead of the written one. Every team measures twice and a second builder checks before cutting.
Goal opening is right but the floor is flat so nothing returns. Ramp the floor at least 10 degrees.
Pacing
Running fast: Take the moving-element Pro Spec: a hinged reset flap.
Running behind: Build the goal only, to exact spec. That alone is a real deliverable.
Spec · everyone reaches this
It gets installed and used for the rest of the year.
Pro Spec · opt in, never assigned by grade
Solves a problem the builder identified themselves, with evidence.
Before the session · guide prep
Photograph the shop as it currently is, mess included, and project it at Shop Meeting.
Have a list of five known shop problems ready in case nobody names one.
Measure the bins, wall, and shelf spaces and post the numbers.
Reserve the last 8 minutes for actual installation. An uninstalled upgrade does not count.
Guided Bench · The Labeled Bin Front
Say each step, wait, say the next. Do not build it for them.
Measure an existing bin.
Cut a face panel that fits the front.
Cut a window in it.
Write the label in big letters.
Tape it on and fill the bin.
Show them first · pick one, not all three
Photograph the shop as it currently is and project it big. Let the mess speak.
Search: makerspace organization pegboard.
Show a tool shadow board and ask what it is for.
Test Bench
Installed, used for a week, reviewed at session 21.
Materials draw $2.06 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Built for a problem that does not exist. Require the builder to name who has the problem.
Nothing gets installed because time ran out. Hard stop at minute 32. Install is not optional.
Pacing
Running fast: Take the evidence Pro Spec: photograph the problem before and after.
Running behind: One labeled bin front, installed. Real and useful.
Spec · everyone reaches this
The client accepts delivery.
Pro Spec · opt in, never assigned by grade
Client interview conducted by the builder before designing anything.
Before the session · guide prep
Collect at least 4 real requests from other guides a week ahead. Written, not verbal.
Sort them yourself into feasible and not feasible before the session.
Arrange for at least one client to be available at the end for delivery.
Guided Bench · The Client Interview Clinic
Say each step, wait, say the next. Do not build it for them.
Guide runs the interview clinic instead of a build.
What three questions do you ask before you build anything for someone?
Write them down.
Then the group builds the simplest accepted request together.
Deliver it in person.
Show them first · pick one, not all three
Read a real request out loud from another guide, unedited.
Show a restaurant order ticket.
Search: design brief example.
Test Bench
The client says yes or no. That is the entire test.
Core skill
Requirements gathering, delivering for a real person
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Brass fastener
3 fastener
45 fastener
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $1.22 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builders design what they want instead of what was asked. Re-read the request aloud at minute 20.
The client is not available and the build has nowhere to land. Have a backup client, always.
Pacing
Running fast: Take the client interview Pro Spec.
Running behind: Fill the simplest request on the list as a whole group.
Arc IV
Commission
Sessions 16 to 20
Learners own the content. Builds are learner-pitched. These three options per session are the Backup Bank.
Handoff
Phase 4: Shop Lead pair runs the session. Guide owns materials, safety, and Test Bench only.
Note
The Backup Bank runs when a pitch falls through, and doubles as a seed list for builders who are stuck on what to pitch.
16
Pitch Day
Arc IV
Shop Meeting question
What makes an idea worth building?
Shop Council reviews every Pitch Card and slots sessions 17 to 24. The build runs alongside the council meeting, so pick something that runs itself.
Spec · everyone reaches this
Finished and tested in 20 minutes.
Pro Spec · opt in, never assigned by grade
Finished in 12.
Before the session · guide prep
Post a visible countdown timer.
Print the session 1 photos and post them beside the build area.
Pre-roll 30 tubes so the 20 minutes is genuinely 20 minutes of building. 15 minutes.
Set up the Shop Council table away from the build area with all Pitch Cards sorted.
Guided Bench · The Tower, Again
Say each step, wait, say the next. Do not build it for them.
Run Tower Trials again (session 1C) with a 20 minute clock and no fan.
Same three tubes, same tripod.
Race the clock, not each other.
Test at the buzzer.
Talk about what took so long in September.
Show them first · pick one, not all three
Open the Shop Book to session 1 and ask why it took a whole hour.
Put a visible countdown on the board.
Search: speed build challenge.
Test Bench
Timer on the wall. When it goes off, hands up, tested as-is.
Core skill
Decisiveness, scoping. Teaches builders what actually fits in one session, which makes their pitches better.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.17 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builders over-plan and run out of clock. Give them 90 seconds of sketch time, not six minutes, today only.
Shop Council debates forever and nothing gets slotted. Give them a hard rule: 3 minutes per card, vote, move on.
Pacing
Running fast: Take the 12 minute Pro Spec, or run a second round.
Running behind: Extend to 25 minutes. The point is the compression, not the exact number.
Spec · everyone reaches this
It measurably beats your old one on the original Test Bench.
Pro Spec · opt in, never assigned by grade
Beat someone else's standing record, not just your own.
Before the session · guide prep
Have the Shop Book and the record board out and visible.
Stage materials for the three most likely rebuild choices: racers, towers, bridges.
Write the current records on the board in large numbers.
Guided Bench · The Improvement Clinic
Say each step, wait, say the next. Do not build it for them.
Guide picks one build, usually the racer, and runs an improvement clinic.
Check wheel alignment first.
Then reduce weight.
Then reduce friction.
One change at a time, test after each. That rule is the lesson.
Show them first · pick one, not all three
The Shop Book, open on the table, every page.
The record board with the current numbers on it.
Ask what they know now that they did not know in September.
Test Bench
Old number and new number, both posted on the record board.
Core skill
Self assessment, iteration, using the Shop Book as a record
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Drinking straw
2 straw
30 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Rubber band
3 band
45 band
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.37 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builder changes five things at once and cannot tell what helped. Enforce one change, then test.
New build is worse and the builder is deflated. That is a result. Post both numbers anyway.
Pacing
Running fast: Take the beat-someone-else's-record Pro Spec.
Running behind: Rebuild the same thing and match the old number. Matching is a skill.
Spec · everyone reaches this
An outside reader agrees your build matches the brief.
Pro Spec · opt in, never assigned by grade
Trade briefs with someone at the halfway mark and finish theirs.
Before the session · guide prep
Write 20 one-line briefs on cards and seal them in envelopes. 25 minutes, and reusable forever.
Make sure every brief is buildable from the standing materials with no special order.
Read one brief aloud and underline the constraint together before handing the rest out.
Guided Bench · The Simple Brief
Say each step, wait, say the next. Do not build it for them.
Guided group gets the simplest brief.
Example: something that moves a marble three feet without you touching it.
Read it together and underline the constraint.
Build it step by step.
Read the brief again at the end and check.
Show them first · pick one, not all three
Hand out sealed envelopes and do not let anyone open them early.
Show a recipe card and ask what is a rule and what is a suggestion.
Search: design constraint challenge.
Test Bench
Briefs read aloud after. The room votes on whether the build matches.
Core skill
Interpretation, constraint work
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Marble
2 marble
30 marble
buy once, reuse
Wooden skewer
2 skewer
30 skewer
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.47 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builder ignores the constraint. Make them read the brief aloud to a neighbor at minute 15.
Brief is ambiguous and two builders read it opposite ways. Both are right. That is the Shop Talk.
Pacing
Running fast: Take the trade-briefs Pro Spec at minute 20.
Running behind: Guided Bench takes the simplest brief and builds it as a group.
17
Learner Pitch, Week 1
Arc IV
Shop Meeting question
Whose problem is worth solving?
Backup Bank theme: builds that solve a real problem. Runs if the scheduled pitch falls through.
Spec · everyone reaches this
The fix gets installed and the person with the problem says it works.
Pro Spec · opt in, never assigned by grade
Interview the person before you design anything.
Before the session · guide prep
Walk the hallway yourself first and list ten annoyances so the board is never empty.
Get permission in advance for anything that gets installed in a shared space. This matters.
Cut a bag of wedge blanks and slotted rectangles. 12 minutes.
Guided Bench · Door Stop and Cord Keeper
Say each step, wait, say the next. Do not build it for them.
Two dead simple, high success fixes.
The door stop: fold a wedge, layer it, test it.
The cord keeper: cut a slotted rectangle and wind the cord.
Install both somewhere real.
Go back next week and see if they are still there.
Show them first · pick one, not all three
Walk the hallway with the club first and list every annoyance on the board.
Show a binder clip being used as a cord holder.
Ask whose job it currently is to fix these things.
Test Bench
Installed and used. Reviewed one week later.
Core skill
Problem finding, user validation
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Duct tape
0.04 roll
0.6 roll
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Zip tie
3 tie
45 tie
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.64 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Fix does not survive one day of real use. Doubled cardboard and taped both sides, always.
Nobody wanted it fixed. Require a named person who has the problem before building starts.
Pacing
Running fast: Take the interview Pro Spec, or return to a previous fix and improve it.
Running behind: Build the door stop. It is small, real, and installed.
Spec · everyone reaches this
Holds the thing, and the thing goes back into it without anyone being asked.
Pro Spec · opt in, never assigned by grade
Fits an existing space to within half an inch, measured.
Before the session · guide prep
Identify three genuinely disorganized spots in the building and photograph them.
Measure the target spaces and post the numbers.
Cut a bag of divider strips with slots pre-cut. 18 minutes.
Guided Bench · The Divided Tray
Say each step, wait, say the next. Do not build it for them.
Cut a rectangle base.
Cut four walls and tape them up.
Cut divider strips with slots halfway down.
Slot them together into a grid.
Drop the grid in and fill it.
Show them first · pick one, not all three
Open a genuinely messy drawer and just look at it together.
Show a tackle box or a toolbox with dividers.
Search: cardboard drawer organizer.
Test Bench
Filled and put in place. Checked at the next session for whether it is actually being used.
Core skill
Measuring, dividers, real permanence
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.16 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Organizer does not fit the space. Measured once, or measured the wrong thing. Two builders measure, independently.
Dividers collapse under weight. Slot them together in a grid instead of gluing them flat.
Pacing
Running fast: Take the half-inch tolerance Pro Spec.
Running behind: A four-wall tray with one divider. Useful on day one.
Spec · everyone reaches this
The person it is for can use it.
Pro Spec · opt in, never assigned by grade
Two different people with two different needs, one design.
Before the session · guide prep
Have everyone write their name with their non-dominant hand as they sit down.
Bring three ordinary objects that are hard to use one-handed.
If a specific person is the client, talk to them first and get their consent to be involved.
Guided Bench · The Built-Up Handle
Say each step, wait, say the next. Do not build it for them.
Wrap a tool handle in layers of corrugated cardboard.
Tape each layer down.
Try using it with a glove on, or with one hand.
Add or remove layers until it feels right.
Hand it to someone else and watch.
Show them first · pick one, not all three
Have everyone write their name with their other hand first.
Show a jar opener or a bent-handle spoon.
Search: adaptive design tools cardboard.
Test Bench
The person uses it in front of everyone.
Core skill
Accessibility, empathy, iteration with a real user. Genuinely Socratic.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Zip tie
4 tie
60 tie
consumed
Modeling clay
2 oz
30 oz
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.09 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builder designs for what they imagine instead of asking. Get the user in the room at minute 20, not minute 38.
Adapter makes the object worse. That is a finding. Say so and iterate.
Pacing
Running fast: Take the two-users Pro Spec.
Running behind: Build up one handle and test it three ways.
18
Learner Pitch, Week 2
Arc IV
Shop Meeting question
What makes a competition fair?
Backup Bank theme: competition.
Spec · everyone reaches this
Your machine competes without breaking.
Pro Spec · opt in, never assigned by grade
Your machine wins two rounds against two different opponents.
Before the session · guide prep
Shop Council writes the win condition the week before and posts it. Do not improvise this.
Tape the arena circle on the floor before builders arrive.
Cut 25 sled bases and 25 wedge fronts. 18 minutes.
Print a blank bracket.
Guided Bench · The Sumo Pusher
Say each step, wait, say the next. Do not build it for them.
Build a low, wide cardboard sled.
Tape a wedge on the front so it slides under things.
Add weight to the back.
Push from a start line on a taped circle.
Whoever leaves the circle loses.
Show them first · pick one, not all three
Search: sumo robot competition.
Run an actual tug of war for two minutes first.
Ask what a machine needs to win that has nothing to do with speed.
Test Bench
Bracket. Everyone watches every match.
Core skill
Competitive design, rule reading, robustness
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Metal washer (test weight)
8 washer
120 washer
buy once, reuse
Duct tape
0.04 roll
0.6 roll
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.18 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Machines destroy each other in round one and the bracket dies. Add a repair window between rounds. Ten minutes.
One design dominates completely. That is a rules finding. Fix the rules for round two, in public.
Pacing
Running fast: Take the two-wins Pro Spec, or design a counter to the dominant machine.
Running behind: Sled and wedge only, no weight system. It competes.
Spec · everyone reaches this
You post a number.
Pro Spec · opt in, never assigned by grade
You break a standing club record.
Before the session · guide prep
Post the current record board with every number visible.
Set up all three test stations (load, distance, height) before builders arrive.
Have the luggage scale, tape measure, and stopwatch out and calibrated.
Guided Bench · The Load Test Station
Say each step, wait, say the next. Do not build it for them.
Build a simple layered beam.
Span it between two chairs.
Add books one at a time and count.
Add one layer and repeat.
Write both numbers on the board.
Show them first · pick one, not all three
The record board itself, with the current numbers written large.
Search: world record engineering challenge.
Ask which record in this room is the softest.
Test Bench
The record board, permanently posted in the shop.
Core skill
Measurement, focused iteration, using data
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Hot glue stick
2.5 stick
37.5 stick
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Drinking straw
2 straw
30 straw
consumed
Metal washer (test weight)
6 washer
90 washer
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.94 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builder measures their own record with nobody watching. Every record needs a witness. Write the witness name.
Everyone picks the same record. Cap it at four builders per record.
Pacing
Running fast: Take the break-a-standing-record Pro Spec.
Running behind: Post any number at all. A baseline is a contribution.
Spec · everyone reaches this
The rules are written down and a stranger could referee from them.
Pro Spec · opt in, never assigned by grade
An actual first grader beats an actual eighth grader.
Before the session · guide prep
Have three example handicap systems ready: golf, a board game catch-up rule, a head start in a race.
Print a blank rules sheet with numbered lines.
Recruit an actual younger learner and an actual older learner to be the test pair, in advance.
Guided Bench · The Rules Clinic
Say each step, wait, say the next. Do not build it for them.
Write one rule.
Now try to cheat your own rule.
Fix the rule.
Repeat twice more.
Then build the thing the rules need.
Show them first · pick one, not all three
Explain a golf handicap in 60 seconds.
Show a board game with a catch-up mechanic and ask why it exists.
Ask whether fair and equal are the same thing. Do not answer.
Test Bench
Run the competition. Then debrief on whether it was actually fair.
Core skill
Rule design, fairness, systems thinking. The most Socratic session of the year.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $1.09 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Rules are so complicated nobody can referee. Cap it at five rules. Read them to a stranger.
The handicap is so heavy the older learner cannot win at all. That is also unfair, and it is a great Shop Talk.
Pacing
Running fast: Take the actual-first-grader-wins Pro Spec.
Running behind: Write the rules, run one match, debrief. No build required.
19
Learner Pitch, Week 3
Arc IV
Shop Meeting question
Who is this actually for?
Backup Bank theme: build for an audience who is not you.
Spec · everyone reaches this
You deliver it and they use it.
Pro Spec · opt in, never assigned by grade
You never tell them what you are making. It has to work on first contact.
Before the session · guide prep
Ask staff in advance who would genuinely use something, and get three names.
Confirm the recipients will be in the building at the end of the session.
Cut a bag of caddy bases and wall strips. 15 minutes.
Guided Bench · The Desk Caddy
Say each step, wait, say the next. Do not build it for them.
Cut a base.
Add three walls.
Add one divider.
Add one label with their name on it.
Deliver it in person, today.
Show them first · pick one, not all three
Ask who in this building has helped them this year. Write the names on the board.
Show something handmade that someone gave you.
Search: handmade gift design.
Test Bench
Delivery, witnessed. Reported back next session.
Core skill
Designing for someone who cannot give you feedback mid-build
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.12 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Gift is generic and clearly for nobody in particular. Require the recipient's name on it before minute 15.
Not delivered, so it does not count. Reserve the last 6 minutes for delivery, walking there included.
Pacing
Running fast: Take the surprise Pro Spec.
Running behind: Base, three walls, one label. Delivered.
Spec · everyone reaches this
A younger learner plays with it for 3 minutes without breaking it.
Pro Spec · opt in, never assigned by grade
They play with it for 3 minutes without asking how it works.
Before the session · guide prep
Arrange the Spark visit in writing a week ahead and confirm the morning of.
Bring a pile of genuinely broken toys and put them on the table.
Cut 60 wheels and 25 doubled body panels. 25 minutes.
Set a hard safety rule: nothing smaller than a golf ball, no sharp edges, no loose small parts. Say it twice.
Guided Bench · The Push Toy
Say each step, wait, say the next. Do not build it for them.
Build the straw axle car.
Double the cardboard everywhere.
Tape a push stick to the back.
Round every single corner.
Hand it to someone and let them try to break it.
Show them first · pick one, not all three
Bring a pile of actually broken toys and pass them around.
Watch a five year old use anything at all for two minutes.
Search: toy safety design for young children.
Test Bench
Actual Spark learners come in and play. Brutal and honest.
Core skill
Durability, intuitive design, designing for someone very different from you
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Drinking straw
2 straw
30 straw
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Wooden dowel, 1/4 in
1 dowel
15 dowel
buy once, reuse
Duct tape
0.06 roll
0.9 roll
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.41 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Breaks in the first 20 seconds. Single-layer cardboard. Double everything a small hand will grab.
Too complicated for a five year old to work out. If it needs explaining, it failed. Simplify it.
Pacing
Running fast: Take the no-questions-asked Pro Spec.
Running behind: A doubled push car with a stick. Indestructible and popular.
Spec · everyone reaches this
An adult who does not know the idea gets it.
Pro Spec · opt in, never assigned by grade
A learner two grades below you gets it.
Before the session · guide prep
Perform one of your own demos live, then break down why it works as a demo.
Cut 25 lever strips and 25 pivot blocks. 15 minutes.
Have a visible 60 second timer and enforce it without exception.
Line up two adults who do not know the ideas to be the audience.
Guided Bench · The Lever Board
Say each step, wait, say the next. Do not build it for them.
Balance a strip on a dowel.
Mark the pivot points along it.
Add weights and move the pivot.
Ask a viewer to predict before each move.
That prediction moment is the whole demo.
Show them first · pick one, not all three
Guide performs one of their own science demos live, then breaks down why it works as a demo.
Search: science demonstration lever fulcrum.
Ask what makes a demo different from an explanation.
Test Bench
60 second demos in front of the whole club. Timer enforced, no exceptions.
Core skill
Teaching through objects, editing an idea down
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Wooden dowel, 1/4 in
1 dowel
15 dowel
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Metal washer (test weight)
6 washer
90 washer
buy once, reuse
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.66 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Demo becomes a lecture with a prop. Rule: the audience has to do or predict something in the first 15 seconds.
Runs long every time. Cut it off at 60 seconds anyway. The cutoff is the lesson.
Pacing
Running fast: Take the younger-audience Pro Spec.
Running behind: One lever, one prediction, 30 seconds.
20
Learner Pitch, Week 4
Arc IV
Shop Meeting question
When does adding one more thing make it worse?
Backup Bank theme: combine mechanisms.
Spec · everyone reaches this
All three run in sequence from one input.
Pro Spec · opt in, never assigned by grade
All three mechanisms run twice in a row without you rebuilding anything.
Why this Pro Spec is reachable in 40 minutes
A self-resetting machine is a serious mechanism problem. Running twice without a rebuild is the same reliability lesson and it is achievable by marking positions and reinforcing joints.
Before the session · guide prep
Build the crank-and-light yourself and run it 10 times. Twice in a row is harder than it sounds.
Pre-cut cam discs and copper tape strips (see 8A and 9A). 30 minutes.
Stage all Arc II bins in one row, labeled.
Guided Bench · The Crank and Light
Say each step, wait, say the next. Do not build it for them.
Build the cam box from session 8.
Add a copper tape contact so the cam closes a circuit at the top of each turn.
The LED blinks once per rotation.
Two mechanisms, one input.
Add a third if there is time.
Show them first · pick one, not all three
Open the back of a wall clock and look at the train of gears.
The Shop Book, Arc II pages, all spread out.
Search: compound machine mechanism.
Test Bench
One input. Everyone watches the whole chain, start to end.
Core skill
Integration, sequencing, debugging
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Wooden skewer
3 skewer
45 skewer
consumed
Drinking straw
2 straw
30 straw
consumed
Brass fastener
4 fastener
60 fastener
consumed
Copper tape
1.5 ft
22.5 ft
consumed
LED, 5mm
2 LED
30 LED
consumed
CR2032 coin cell
1 cell
15 cell
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.59 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Two mechanisms work, the third kills both. Build and test each one alone before connecting anything.
Works once then never again. Nothing is marked. Trace every part's position on the base.
Pacing
Running fast: Take the twice-in-a-row Pro Spec, or add a fourth mechanism.
Running behind: Two mechanisms, one input. That is a compound machine.
Spec · everyone reaches this
The old function still works and the new one does too.
Pro Spec · opt in, never assigned by grade
The upgrade is removable, and the build still works without it.
Before the session · guide prep
Retrieve the Arc II builds from storage, or plan to rebuild a base first. Check storage the week before.
Stage gears, cams, circuits, and linkages in separate labeled bins.
Have the Shop Book Arc II pages open on a table.
Guided Bench · The Add-a-Gear Clinic
Say each step, wait, say the next. Do not build it for them.
Take the session 8 gearbox.
Mesh one more gear onto the end.
Before turning it, predict which way the new gear will spin.
Turn it and check.
Add one more and predict again.
Show them first · pick one, not all three
Show a phone case, a bike rack, anything that clips on and off.
Search: modular design product.
Ask what they would lose if the upgrade broke.
Test Bench
Tested with the upgrade on, then off. Both have to pass.
Core skill
Modularity, not breaking what already works
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Brass fastener
5 fastener
75 fastener
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Plastic gear, assorted
2 gear
30 gear
buy once, reuse
Copper tape
1 ft
15 ft
consumed
LED, 5mm
1 LED
15 LED
consumed
CR2032 coin cell
1 cell
15 cell
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $1.99 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Upgrade breaks the original function. Test the original first and write down what it did.
Upgrade is glued on permanently. For the Pro Spec it has to come off. Fasteners and tape, not glue.
Pacing
Running fast: Take the removable Pro Spec.
Running behind: Add one gear to the gearbox and predict the direction. Complete.
Spec · everyone reaches this
It behaves the same way three times in a row.
Pro Spec · opt in, never assigned by grade
Nobody guesses your mechanism correctly.
Before the session · guide prep
Build a mystery tube and let builders pull it as they arrive, without saying anything.
Cut and punch 25 boxes with four holes each. 20 minutes.
Have a rule ready: no opening any box until everyone has guessed. Enforce it.
Guided Bench · The Mystery Tube
Say each step, wait, say the next. Do not build it for them.
Cross two strings inside a box with four holes.
Tie them so pulling one moves another in an unexpected way.
Seal the box completely.
Let people pull the strings.
Do not open it until every single person has guessed.
Show them first · pick one, not all three
Search: mystery tube science inquiry.
Do a simple magic trick and explain it afterward.
Ask how you can know something is true if you cannot see it.
Test Bench
Three runs, then the room guesses, then the box opens.
Core skill
Reliability, encapsulation, inference. Deeply Socratic on the guessing side.
Supplies
Item
Per builder
For 15
Shoe box or small box
1 box
15 box
free / donated
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
String or twine
6 ft
90 ft
consumed
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Brass fastener
3 fastener
45 fastener
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.43 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Box behaves differently every pull. Strings are tangling. Route them cleanly and anchor the crossing point.
Someone opens a box early. Restart that box with a new mechanism. Natural consequence.
Pacing
Running fast: Take the nobody-guesses Pro Spec.
Running behind: Two holes and one string. Still a mystery.
Arc V
The Shop Is Theirs
Sessions 21 to 25
Learners run everything, including Test Bench. The year ends with a public Build Expo they run themselves.
Handoff
Phase 5: Guide is the adult in the room, the person who owns the box cutter, and nothing else.
Note
Session 21 is an entry point run entirely by learners. Session 25 is the recruiting engine for next year and it costs almost nothing.
21
Entry Point and Shop Reset
Entry pointArc V
Shop Meeting question
What does this shop owe a person who just walked in?
Final entry point of the year. New builders are onboarded entirely by learners. Second half is Shop Council governance: rank promotions, job reassignment, and the pitch calendar for 22 to 24.
Spec · everyone reaches this
The new builder's build passes Test Bench.
Pro Spec · opt in, never assigned by grade
You never touch their build.
Before the session · guide prep
Print Shop License cards, one per new builder.
Assign every returning builder a new builder by name, before the session.
Pick the build in advance and make it one from Arc I that the returning builder already knows cold.
Post the rank board where new builders see it on the way in.
Guided Bench · The License Station
Say each step, wait, say the next. Do not build it for them.
Guide runs the license station only.
The three cuts: score and fold, slot, notch.
The two safety rules.
The one cleanup rule.
Everything else in the room is learner run.
Show them first · pick one, not all three
The Shop Book, from page one.
The rank board with everyone's names on it.
The session 1 photos next to today's builds.
Test Bench
New builders' builds tested first, and loudest.
Core skill
The whole license, taught by learners
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Wooden skewer
2 skewer
30 skewer
consumed
Drinking straw
2 straw
30 straw
consumed
Cardstock sheet
1 sheet
15 sheet
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.39 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Teacher takes over the new builder's build. Chairs back one foot. It works every time.
New builder finishes nothing and leaves discouraged. The teacher's job is the new build passing, not their own.
Pacing
Running fast: Take the never-touch-it Pro Spec.
Running behind: Teach the license and one technique. That is a full first session.
Spec · everyone reaches this
The rule is posted and the object that enforces it exists.
Pro Spec · opt in, never assigned by grade
A rule that removes the need for an adult to enforce it.
Before the session · guide prep
Pull the current rules and post them, including the ones nobody follows.
Have the shop's actual recurring problems listed from your session logs.
Cut 25 sign blanks and stage thick markers. 12 minutes.
Get permission for anything mounted on a wall.
Guided Bench · The Sign
Say each step, wait, say the next. Do not build it for them.
Cut a panel.
Big letters, five words maximum.
One color only.
Mount it where the problem happens, not by the door.
Check it in a week and see if it worked.
Show them first · pick one, not all three
Look at airport signage and ask why there are so few words.
Show a tool shadow board.
Search: visual management workplace signs.
Test Bench
The next four sessions. Rules that get ignored come back to council.
Core skill
Governance, building systems that replace supervision
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Cardstock sheet
3 sheet
45 sheet
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Duct tape
0.03 roll
0.4 roll
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $1.99 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Rules written that nobody can enforce. Ask who enforces it and how they would know.
Sign has 30 words on it. Five words. Hold the line.
Pacing
Running fast: Take the no-adult-needed Pro Spec. A tool shadow outline is the classic answer.
Running behind: One sign, mounted where the problem happens.
Spec · everyone reaches this
Sealed, labeled, and it survives storage.
Pro Spec · opt in, never assigned by grade
Contains a working machine that still works in a year.
Before the session · guide prep
Decide where the capsule will actually be stored and confirm it will survive there.
Print letter templates: Dear next year's club.
Cut 8 strong box shells and lids for group capsules. 20 minutes.
Guided Bench · The Sealed Box
Say each step, wait, say the next. Do not build it for them.
Build a strong box with a lid.
Layer the corners.
Write the open-on date huge across the top.
Put in one build and one letter.
Tape it shut in front of everyone.
Show them first · pick one, not all three
Search: time capsule contents.
Show a sealed shipping crate and ask what makes it survive.
Ask what they wish someone had told them at session 1.
Test Bench
Opened next year. The only build in the program with a one-year test cycle.
Core skill
Durability over time, writing for a future stranger
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Duct tape
0.07 roll
1.1 roll
consumed
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $1.42 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Capsule is flimsy and will not survive storage. Layer the corners and tape every seam twice.
Nobody writes the letter. Letter first, build second. Reverse the order.
Pacing
Running fast: Take the still-works-in-a-year Pro Spec. A purely mechanical build is the safe answer.
Running behind: One box, one letter, one object. Sealed.
22
Learner Pitch, Week 5
Arc V
Shop Meeting question
How big is too big for one session?
Backup Bank theme: ambitious builds. Shop Leads run this session end to end, including Test Bench.
Spec · everyone reaches this
At the end of session 22 you have a working part, not a pile.
Pro Spec · opt in, never assigned by grade
Your session 22 stopping point is a thing that already does something.
Before the session · guide prep
Have every team write their milestone on an index card at minute 8 and post it.
Set up labeled storage for in-progress builds. If work cannot be stored safely, this option does not run.
Photograph every build at the end for the Shop Book.
Guided Bench · The Milestone Clinic
Say each step, wait, say the next. Do not build it for them.
Ask: what is the smallest version of your build that already does something?
Write that down.
Build only that today.
Test it.
Everything else is session 23.
Show them first · pick one, not all three
Show a house under construction with a framed but unfinished room.
Show a half-built model kit and ask if it is a failure.
Search: minimum viable product.
Test Bench
End of 22, every team demos whatever works so far. Piles fail.
Core skill
Scoping, milestones, stopping well
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Brass fastener
4 fastener
60 fastener
consumed
Wooden skewer
3 skewer
45 skewer
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $0.60 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
End of session is a pile with nothing working. The milestone was too ambitious. Cut it at minute 8, not minute 38.
Work gets damaged between sessions. Labeled bins, off the floor, decided before the session.
Pacing
Running fast: Take the already-does-something Pro Spec.
Running behind: Halve the milestone. A working quarter beats a broken whole.
Spec · everyone reaches this
It stands and does its one job.
Pro Spec · opt in, never assigned by grade
It comes apart and goes back together in 5 minutes.
Before the session · guide prep
Cut 60 panels with matching slots using a jig (see 14A). 45 minutes.
Decide the structure in advance and sketch it on the board.
Clear the floor entirely and confirm the ceiling height.
Guided Bench · The Panel Factory
Say each step, wait, say the next. Do not build it for them.
Run the panel factory from session 14.
Cut identical panels with identical slots.
Supply the whole club.
Track how many panels the structure needs.
That count is the plan.
Show them first · pick one, not all three
The session 14 photos in the Shop Book.
Search: giant cardboard sculpture.
Show a parade float being built.
Test Bench
Built, disassembled, rebuilt against the clock.
Core skill
Scale, joinery, coordination
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
6 sheet
90 sheet
free / donated
Duct tape
0.07 roll
1.1 roll
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.57 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Leans and folds. No diagonals. Panels alone never hold at scale.
Too tall to reach safely. Cap the height at what a standing builder can reach without a chair. No chairs.
Pacing
Running fast: Take the 5 minute reassembly Pro Spec.
Running behind: Half the height, fully braced.
Spec · everyone reaches this
Every builder makes at least three.
Pro Spec · opt in, never assigned by grade
The group effect is visible from across the room.
Before the session · guide prep
Build one unit and cut a full template set from it. 25 minutes.
Pre-cut enough blanks for 40 units. Mass production needs stock ready. 30 minutes.
Mark a baseboard grid on the floor for the assembly.
Guided Bench · The Jig
Say each step, wait, say the next. Do not build it for them.
Build one unit carefully.
Cut a cardboard template of every piece.
Trace and cut ten sets.
Assemble on a marked baseboard.
Speed now matters more than perfection. Say that out loud.
Show them first · pick one, not all three
Show a starling murmuration clip.
Search: kinetic sculpture many parts.
Show an assembly line and ask what the jig is doing.
Test Bench
All of them run at once.
Core skill
Mass production, jigs and templates, emergence
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Cardstock sheet
4 sheet
60 sheet
consumed
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Wooden skewer
3 skewer
45 skewer
consumed
Brass fastener
4 fastener
60 fastener
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.67 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Every unit is slightly different and nothing lines up. Templates, not eyeballing. Say it twice.
Builders perfect unit one and never make units two and three. Quantity today. Say so out loud.
Pacing
Running fast: Take the visible-from-across-the-room Pro Spec.
Running behind: Two units each instead of three. The effect still reads.
23
Learner Pitch, Week 6
Arc V
Shop Meeting question
What are we actually proud of?
Backup Bank theme: build for the Expo. Everything made from here forward is going in front of visitors.
Spec · everyone reaches this
It works when a stranger operates it.
Pro Spec · opt in, never assigned by grade
It survives 20 strangers operating it.
Before the session · guide prep
Put a rough build next to a finished build and let them compare without commentary.
Stage a finishing station: cardstock for labels, markers, trimming tools, fresh tape.
Book the three testers from outside the club in advance.
Guided Bench · The Finishing Clinic
Say each step, wait, say the next. Do not build it for them.
Hide the tape.
Clean up every edge.
Add a label.
Add your name.
Ten minutes of finishing changes everything. Prove it with a before and after.
Show them first · pick one, not all three
Show a great science fair board next to a bad one.
Search: maker faire booth.
Read a museum object label out loud and count the words.
Test Bench
Handed to three builders who did not make it. If they break it, it is not ready.
Core skill
Durability, showmanship, finishing
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
4 sheet
60 sheet
free / donated
Cardstock sheet
3 sheet
45 sheet
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Duct tape
0.04 roll
0.6 roll
consumed
Brass fastener
4 fastener
60 fastener
consumed
Sketch paper sheet
2 sheet
30 sheet
consumed
Materials draw $2.21 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Breaks the first time a stranger uses it. Nobody tested it on a stranger. Hand it over at minute 25, not minute 39.
Ten minutes of finishing skipped in favor of one more feature. Hard stop for finishing at minute 28.
Pacing
Running fast: Take the 20-strangers Pro Spec.
Running behind: Finish what exists. A finished simple build beats an unfinished ambitious one at an expo.
Spec · everyone reaches this
A visitor finishes it in 15 minutes with no help.
Pro Spec · opt in, never assigned by grade
Materials for 30 visitors fit in one bin.
Before the session · guide prep
Build one perfect drop-in kit as the model: one template, three steps, one bin, one sign. 25 minutes.
Recruit a Spark learner and a parent as testers, confirmed in advance.
Have bins and label materials ready.
Guided Bench · The Kit Model
Say each step, wait, say the next. Do not build it for them.
Guide models one perfect drop-in kit.
One template. Three steps. One bin. One sign.
Then the group builds their own to the same format.
Test it on each other.
Cut a step if it runs long.
Show them first · pick one, not all three
Show an IKEA instruction sheet with no words on it.
Search: maker activity kit.
Ask what a visitor should be able to do without asking a question.
Test Bench
Test it on a Spark learner and on a parent. Both have to finish.
Core skill
Instructional design by learners, kitting, testing on real users
Supplies
Item
Per builder
For 15
Cardstock sheet
6 sheet
90 sheet
consumed
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.06 roll
0.9 roll
consumed
Hot glue stick
1.5 stick
22.5 stick
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Sketch paper sheet
4 sheet
60 sheet
consumed
Drinking straw
2 straw
30 straw
consumed
Paper clip
3 clip
45 clip
consumed
Materials draw $2.13 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Takes 40 minutes, not 15. Time it with a real tester and cut a step.
Instructions need a builder standing there. Then they are not instructions. Rewrite as pictures.
Pacing
Running fast: Take the 30-visitors-in-one-bin Pro Spec.
Running behind: Three steps, one template, tested once. That is a kit.
Spec · everyone reaches this
A visitor understands what this club is without a builder talking.
Pro Spec · opt in, never assigned by grade
Includes a build that failed, honestly labeled.
Before the session · guide prep
Print every Shop Book photo from the year. All of them. 30 minutes at a copy shop or the office printer.
Cut 6 large display panels. 20 minutes.
Draft the twenty-word arc summaries yourself as a fallback.
Confirm where the wall will be and get permission.
Guided Bench · The Panel
Say each step, wait, say the next. Do not build it for them.
One panel per arc.
Three photos and twenty words per panel.
One real object mounted on each.
Big title across the top.
Mount it at kid height, not adult height.
Show them first · pick one, not all three
The Shop Book, all of it, spread across a table.
Search: exhibition panel design.
Ask which failure this year they would actually want to show.
Test Bench
Ask a parent to walk it and then say back what the club does.
Core skill
Curation, honesty, editing
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
6 sheet
90 sheet
free / donated
Cardstock sheet
4 sheet
60 sheet
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Masking tape
0.07 roll
1.1 roll
consumed
Hot glue stick
2 stick
30 stick
consumed
Painter's tape
0.05 roll
0.8 roll
consumed
Sketch paper sheet
3 sheet
45 sheet
consumed
Materials draw $2.16 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Panels are all text and nobody reads them. Twenty words. Count them out loud.
Only the successes are shown. Require one honest failure panel. It is the most interesting thing on the wall.
Pacing
Running fast: Take the honest-failure Pro Spec.
Running behind: Three panels instead of five. Cover the arcs that matter most.
24
Dress Rehearsal
Arc V
Shop Meeting question
What breaks when someone else touches your work?
Last session before the Expo. Nothing new gets started today.
Spec · everyone reaches this
The whole thing runs once without a guide speaking.
Pro Spec · opt in, never assigned by grade
A guide from another studio walks through and cannot find a gap.
Before the session · guide prep
Write the full run of show: every station, who staffs it, what they say first.
Book one outside adult to walk it cold. Confirm the day before.
Set the room up exactly as it will be on Expo day. Exactly.
Have a clipboard for the gap list.
Guided Bench · The Confused Visitor
Say each step, wait, say the next. Do not build it for them.
Guide plays the confused visitor.
Loudly. Repeatedly. In the way.
Ask the questions a real visitor would ask.
Write down every gap.
That list is the job for the last ten minutes.
Show them first · pick one, not all three
Search: event run of show.
Describe a theater tech rehearsal.
Show a restaurant's pre-service lineup.
Test Bench
An outside adult walks it cold and reports every confusion out loud.
Core skill
Rehearsal, role clarity, catching the thing you forgot
Supplies
Item
Per builder
For 15
Cardstock sheet
3 sheet
45 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Masking tape
0.06 roll
0.9 roll
consumed
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Sketch paper sheet
3 sheet
45 sheet
consumed
Materials draw $1.02 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Rehearsal turns into more building. Nothing new gets built today. State it at Shop Meeting.
The gap list gets made and never acted on. Reserve the last 10 minutes for fixes only.
Pacing
Running fast: Take the outside-guide-finds-no-gap Pro Spec, or run it a second time.
Running behind: Rehearse the three busiest stations only.
Spec · everyone reaches this
Your build survives and still works.
Pro Spec · opt in, never assigned by grade
You repair it in the same session and it survives a second round.
Set a clear ceiling on what counts as hard use. Demonstrate it yourself first.
Guided Bench · The Repair Station
Say each step, wait, say the next. Do not build it for them.
The three repairs that fix 90 percent of cardboard failures.
The corner gusset: a triangle glued into a weak corner.
The doubled panel: a second layer, corrugation turned 90 degrees.
The re-taped hinge: fresh tape on both sides.
Practice all three on scrap first.
Show them first · pick one, not all three
Bring a well-worn hand tool and a library book that survived 20 years.
Search: product durability testing.
Ask what it feels like to watch someone break your thing.
Test Bench
Round one, then a repair window, then round two.
Core skill
Robustness, repair, ego management
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Masking tape
0.09 roll
1.3 roll
consumed
Duct tape
0.05 roll
0.8 roll
consumed
Hot glue stick
2.5 stick
37.5 stick
consumed
Cardstock sheet
2 sheet
30 sheet
consumed
Sketch paper sheet
1 sheet
15 sheet
consumed
Materials draw $0.61 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Builders are upset when their work breaks. Frame it before, not after: everything breaks today, that is the point.
Testing turns destructive. Demonstrate the exact level of force and hold to it.
Pacing
Running fast: Take the repair-and-survive-round-two Pro Spec.
Running behind: One round of testing, then repairs. Skip round two.
Spec · everyone reaches this
It exists physically and it is in the Shop Book.
Pro Spec · opt in, never assigned by grade
A guide who has never run this club could use it.
Before the session · guide prep
Print blank Challenge Card templates.
Have the Shop Book out with the gaps visibly flagged.
Line up one guide who has never run the club to be the test reader.
Guided Bench · The Challenge Card Clinic
Say each step, wait, say the next. Do not build it for them.
Write a Challenge Card for a build you know cold.
Trade cards with someone.
Build only from their card. No questions allowed.
Mark every place you got stuck.
Give the card back with the marks on it.
Show them first · pick one, not all three
The Shop Book, and the gaps in it.
Show a recipe written badly and try to follow it exactly.
Search: standard operating procedure.
Test Bench
Hand the Shop Book to a guide who has never seen it and ask them to run session 7 from it.
Core skill
Documentation, legacy, thinking past yourself
Supplies
Item
Per builder
For 15
Cardstock sheet
4 sheet
60 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Cardboard sheet, large (approx 18x24)
2 sheet
30 sheet
free / donated
Masking tape
0.05 roll
0.8 roll
consumed
Hot glue stick
1 stick
15 stick
consumed
Sketch paper sheet
4 sheet
60 sheet
consumed
Materials draw $1.16 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Cards assume knowledge the reader does not have. That is exactly what the trade-and-build reveals. Let it happen.
Nobody wants to write. Frame it as: what do you wish someone had left you in September?
Pacing
Running fast: Take the guide-could-run-it Pro Spec and actually test it.
Running behind: Write one card, trade it, mark it up. Done.
25
The Build Expo
Arc V
Shop Meeting question
What did you build that you could not have built in September?
Public. Families, other studios, the robotics team. Learners run it end to end. Shop Leads for next year are named and the founding Shop Council is announced.
Spec · everyone reaches this
Every builder shows one build and answers questions about it.
Pro Spec · opt in, never assigned by grade
Live Test Bench demos, including one deliberate failure demo.
Before the session · guide prep
Confirm the date, the room, and the invite list three weeks out.
Print the Shop Book and mount it on a stand at the entrance.
Set the drop-in station with kits for 30 visitors.
Assign every station a named builder and a backup. Post the list.
Charge a camera and assign a Documentarian.
Guided Bench · The Guide's Only Job
Say each step, wait, say the next. Do not build it for them.
Guide holds the door.
Guide guards the glue guns.
Guide says nothing else.
Seriously, nothing else.
Take photos for the Shop Book.
Show them first · pick one, not all three
Last year's photos, printed and pinned up.
The Shop Book on a stand at the entrance.
Search: maker faire student showcase.
Test Bench
Visitors leave having built something themselves.
Core skill
All of it
Supplies
Item
Per builder
For 15
Cardstock sheet
5 sheet
75 sheet
consumed
Washable marker
1 marker
15 marker
buy once, reuse
Masking tape
0.07 roll
1.1 roll
consumed
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Duct tape
0.04 roll
0.6 roll
consumed
Sketch paper sheet
4 sheet
60 sheet
consumed
Paper plate
2 plate
30 plate
consumed
Materials draw $1.37 per builder (low cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Guide starts talking and takes over. Stand by the door. Physically.
Visitors watch but do not touch. The drop-in station has to be the first thing they see.
Pacing
Running fast: Take the deliberate-failure-demo Pro Spec. It is the most memorable thing at the whole event.
Running behind: Cut to builds and the drop-in station. Skip the demos.
Spec · everyone reaches this
Every station has a leaderboard a visitor can join.
Pro Spec · opt in, never assigned by grade
A visitor beats a builder at their own station.
Before the session · guide prep
Build the master scoreboard the week before.
Set every station's scoring rule in writing and post it at the station.
Print leaderboard sheets, one per station.
Confirm the room and invite list three weeks out.
Guided Bench · The Scoreboard
Say each step, wait, say the next. Do not build it for them.
Guide runs the master scoreboard and nothing else.
Post it where everyone walks past.
Update it out loud.
Announce every new record.
Hand the marker to a learner by the halfway point.
Show them first · pick one, not all three
An arcade high score screen.
Search: carnival game booth.
A county fair midway.
Test Bench
The leaderboards fill up or they do not.
Core skill
Showmanship, running an event
Supplies
Item
Per builder
For 15
Cardstock sheet
6 sheet
90 sheet
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Masking tape
0.07 roll
1.1 roll
consumed
Cardboard sheet, large (approx 18x24)
3 sheet
45 sheet
free / donated
Sketch paper sheet
5 sheet
75 sheet
consumed
Paper plate
2 plate
30 plate
consumed
Materials draw $2.06 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Scoring is inconsistent and visitors argue. One written rule per station, posted, no exceptions.
One station has a queue and the rest are empty. Spread the strongest builds across the room.
Pacing
Running fast: Take the visitor-beats-a-builder Pro Spec and announce it loudly when it happens.
Running behind: Three leaderboard stations instead of eight.
Spec · everyone reaches this
Every request gets a yes or a reasoned no, in writing.
Pro Spec · opt in, never assigned by grade
You fill a request you had no idea was coming.
Before the session · guide prep
Print request cards and set up a submission box at the entrance.
Stage every material bin in the open, fully stocked, before doors.
Brief the sorters on what feasible means in 45 minutes.
Print reasoned-no cards so a decline is still a real answer.
Guided Bench · The Request Queue
Say each step, wait, say the next. Do not build it for them.
Guide sorts incoming request cards into feasible and not.
Hands the feasible ones to open builders.
Writes the reasoned no on the rest.
Keeps the queue moving.
Does not build anything.
Show them first · pick one, not all three
A caricature artist working a fair.
A blacksmith demonstrating at a festival.
Search: live making demonstration.
Test Bench
Requests filled, counted, and handed over on the spot.
Core skill
Improvisation under an audience. The purest proof of the year.
Supplies
Item
Per builder
For 15
Cardboard sheet, large (approx 18x24)
5 sheet
75 sheet
free / donated
Cardstock sheet
5 sheet
75 sheet
consumed
Masking tape
0.09 roll
1.3 roll
consumed
Hot glue stick
3 stick
45 stick
consumed
Washable marker
2 marker
30 marker
buy once, reuse
Sketch paper sheet
5 sheet
75 sheet
consumed
Brass fastener
4 fastener
60 fastener
consumed
Materials draw $2.29 per builder (medium cost week).
Cardboard, boxes, tubes, caps and bottles come from the donation pipeline and are budgeted at zero.
When it breaks · the two usual ones
Requests flood in and the queue stalls. Cap it: one request per visitor, and post the cap.
Every request is impossible. Put three example requests in the box before doors open to set expectations.
Pacing
Running fast: Take the surprise-request Pro Spec.
Running behind: Take requests for 20 minutes only, then close the queue and fill what you have.
06
Budget
Every figure below is computed from the itemised supply lists on the 78 activity pages, not estimated. Three things make it accurate: quantities are per builder and multiplied by 15; purchases round up to whole packs, because you cannot buy 0.4 of a tape multipack; and durable components are bought once at the largest single-session requirement rather than summed across sessions, since motors, syringes, gears, buzzers, and marbles go back in the bin.
$1,113Full year, recommended plan
$139Per learner at 8 enrolled
$5.56Per learner per session
$1,300Ceiling if you pick every expensive option
Scenario
Materials for 15
Tools & program
+15% contingency
Total
Per learner at 8
Cheapest option every week
$350
$516
$130
$996
$124
Recommended option every week
$452
$516
$145
$1,113
$139
Most expensive option every week
$610
$516
$169
$1,295
$162
Budget for $1,350 for the year. Tools and program printing are $516 of that and carry into future years, so year two runs at roughly $717. If enrollment reaches 15, per-learner drops to $74.
Full-year shopping list, recommended plan
Item
Qty needed
Buy
Cost
Type
Hot glue stick
607.5 stick
4 x 200
$72.00
consumable
Masking tape
24.7 roll
5 x 6
$37.50
consumable
Cardstock sheet
525 sheet
3 x 250
$36.00
consumable
Washable marker
30 marker
3 x 12
$27.00
buy once
Brass fastener
795 fastener
2 x 500
$24.00
consumable
Duct tape
3.9 roll
2 x 3
$20.00
consumable
Wooden dowel, 1/4 in
15 dowel
1 x 25
$20.00
buy once
CR2032 coin cell
45 cell
1 x 50
$18.00
consumable
Syringe, 10cc
30 syringe
1 x 30
$18.00
buy once
Copper tape
60 ft
2 x 30
$16.00
consumable
Sketch paper sheet
540 sheet
2 x 500
$16.00
consumable
Marble
60 marble
1 x 200
$15.00
buy once
Ping pong ball
15 ball
1 x 60
$15.00
buy once
Vinyl tubing, 1/8 in
15 ft
1 x 25
$12.00
buy once
Binder clip
90 clip
1 x 100
$10.00
buy once
Drinking straw
180 straw
1 x 500
$10.00
consumable
LED, 5mm
75 LED
1 x 100
$10.00
consumable
Rubber band
165 band
1 x 500
$10.00
consumable
Wooden skewer
390 skewer
1 x 500
$10.00
consumable
Zip tie
105 tie
1 x 200
$10.00
consumable
Painter's tape
0.8 roll
1 x 3
$9.00
consumable
String or twine
105 ft
1 x 500
$8.00
consumable
Plastic cup
75 cup
1 x 100
$6.00
consumable
Rhinestone or sequin sticker
90 gem
1 x 100
$6.00
consumable
Yarn or lanyard cord
30 ft
1 x 50
$6.00
consumable
Paper clip
30 clip
1 x 500
$5.00
consumable
Paper plate
30 plate
1 x 100
$5.00
consumable
Total materials
$451.50
Free and donated, budgeted at zero
Cardboard sheet, large (approx 18x24)
1170 sheet
free / donated
Chipboard (cereal box panel)
15 panel
free / donated
Shoe box or small box
45 box
free / donated
Translate that cardboard figure before you panic: a large appliance box yields roughly 8 to 10 usable panels, so the year needs about 5 to 6 large boxes a week. Send the donation ask in the first parent newsletter, and ask an appliance store and a bike shop. Both usually say yes.
Tools and one-time purchases
Bought once, carried into future years. Clear anything the shop already owns.
Item
Qty
Unit
Line
Why
Low-temp glue gun
5
$8.00
$40.00
Guided Bench table plus two Open Bench stations
Cutting mat
4
$10.00
$40.00
One per cutting station
Metal safety ruler
6
$5.00
$30.00
Scoring and straight cuts
Scissors
15
$2.00
$30.00
One per builder
Box cutter, guide-controlled
2
$6.00
$12.00
Guide only. Never left on a table.
Kid-safe cardboard saw
8
$6.00
$48.00
The single biggest quality upgrade in the list
Hole punch
4
$4.00
$16.00
Brass fastener holes
Awl or push-pin punch
2
$7.50
$15.00
Starting skewer holes
Box fan
1
$30.00
$30.00
Test Bench: wind testing
Luggage scale
1
$12.00
$12.00
Test Bench: load testing
Stopwatch
3
$6.00
$18.00
Test Bench: timed runs
Tape measure, 25 ft
4
$5.00
$20.00
Test Bench: distance runs
Storage bin, labeled
8
$6.00
$48.00
Materials wall
Label maker and tape
1
$15.00
$15.00
Materials wall
Protractor, large
2
$4.00
$8.00
Session 7 launch angles
Kitchen scale, grams
1
$14.00
$14.00
Payload and weight specs
Shop Book binder and sheet protectors
1
$25.00
$25.00
The substitute-proof artifact
Challenge Card and Pitch Card printing, cardstock
1
$30.00
$30.00
Full 25-session set
Rank board and badge printing
1
$25.00
$25.00
Ranks, jobs, records
Expo signage, table covers, printing
1
$40.00
$40.00
Session 25
Total
$516.00
Pack sizes and prices are planning estimates for Bay Area bulk suppliers, mid 2026. The spreadsheet has a Materials Master tab where a real quote can be dropped in and everything recalculates.
07
Guide's field kit
The rule that makes it Socratic
No Rescue
When a build fails during the sprint, the guide's entire vocabulary is three questions: What have you tried? What do you think is happening? Who in this room has solved this? The third is the workhorse. It routes help to a peer, protects a solo guide's attention, and builds the mentoring culture the handoff depends on.
Shop Meeting question bank
What makes a rule worth agreeing to, instead of a rule you were just told?
What's the difference between a mistake and a failure?
Should you copy a design that works?
Is it better to make something strong or make something light?
If your build worked the first time, did you learn anything?
Would you rather build one great thing or five okay things?
When is it time to stop improving something?
Is it cheating to use a better material than everyone else?
Is the best builder in the room the one with the best build?
Who owns an idea in this shop?
Is it harder to build something or to teach someone to build it?
What do you owe someone who helped you?
Should the shop have a leader?
What is the point of a plan if you are going to change it?
What makes a rule worth following when nobody is watching?
Is a build that broke during testing a success or a failure?
What makes an idea worth building?
Whose problem is worth solving?
What makes a competition fair?
Who is this actually for?
When does adding one more thing make it worse?
What does this shop owe a person who just walked in?
How big is too big for one session?
What are we actually proud of?
What breaks when someone else touches your work?
What did you build that you could not have built in September?
The Pitch Card
Filled out by a builder or pair who wants to run a session in the 17 to 24 block. Reviewed by the Shop Council, not the guide. The Socratic question line forces the pitcher to think about the session as a learning experience and not just a cool thing to make.
BUILD NAME:
THE CHALLENGE (one sentence a new builder would understand):
SPEC (how we know it worked):
PRO SPEC (the harder version):
GUIDED BENCH (the simple version, in five steps):
MATERIALS I NEED:
TEST BENCH (how we test it, in front of everyone):
MY SOCRATIC QUESTION:
WHY THIS BUILD:
Recovery Cards
Three zero-prep Challenge Cards for any session where the learner-led plan collapses. Any adult runs them cold.
Span
Bridge the gap between two tables. Materials are on the table. Go.
Drop
Protect an egg from a 10 foot drop using only what is in the bin.
Beat It
Pick any build from the year's Shop Book photos and beat it. Test Bench decides.
When a Recovery Card runs, the Shop Talk questions change to: What did we not prepare? and Whose job was that? Handled without shame, that is the most durable leadership lesson in the 25 weeks.
The five shop jobs
Job
What they own
Stock Keeper
Runs the materials wall, sets out the session's stock, reports what is running low
Test Captain
Sets up and runs the Test Bench for the full 40 minutes, calls pass or fail
Timekeeper
Owns the clock, calls the Freeze, calls Reset
Documentarian
Photographs every build, writes the one-line session log in the Shop Book
Reset Crew Chief
Assigns and verifies cleanup. Shop closes clean or it does not close.
08
For Mo & Clare
Entry points
Five designated Open Shop sessions: 1, 6, 11, 16, 21. Between them anyone can still join, because every build is self-contained. Chaos is capped by build stations, not by dates, and the Shop Council manages that number themselves from session 21.
Age and level
Spec and Pro Spec on every build, both opt-in, neither ever assigned by grade. Sixth through eighth graders are the leadership: they run the Guided Bench, take Apprentices, sit on Shop Council, and build the arena the robotics team competes in. Robotics stays the grades 4 and up offering.
Handoff
Five phases, guide load 100 to 80 to 55 to 30 to 10 percent. The Guided Bench is the key mechanism: a defined job with a written script, which makes it the cleanest thing in the program to hand to a learner.
Scalability
The 75-page printed binder is the real answer, and it is written to be run by someone who is not Jordan. Plus the materials system with a live planning spreadsheet, four to eight Shop Leads who become next year's founding council, and a pitch archive so year two opens easier than year one.
Socratic and hands-on
One unresolved question opens every session. No Rescue limits the guide to three questions during the build. Shop Talk is two questions with no adult praise. Testing is public. There is no session in the 25 without a physical build.
Cost
Budget for $1,350 for the year. That is roughly $169 per learner priced against 8, or $90 if the club fills to 15. $516 of it is tools and printing that carry forward, so year two is closer to $597.
Suggestions
A few things worth thinking through
1. Age floor: Kindergarten, or start at 1st? K works in this design, but the Apprentice model needs enough Certified Builders in place to support them, which won't be true until around session 6.
2. Enrollment cap: 15 builders, capped by build stations, works well with this materials plan.
3. Session 25 Expo: attaching it to an existing school event, rather than standing up a separate evening, would lower the lift considerably.
4. Robotics coordination: session 15 builds the arena the robotics team competes in, so the arena spec is worth locking in writing by roughly session 12.
5. Materials pipeline: the cardboard donation ask is worth sending in the first parent newsletter of the year. The plan needs about 5 to 6 large boxes a week.
6. Prep time: the plan assumes 10 to 30 minutes of guide prep per session, and that assumption is load-bearing. Worth protecting that time deliberately rather than assuming it'll be there.