Puzzle Box TV - xTool Projects
You need a custom gift for men? How about a very personal and tricky puzzle box? Build this box and your friend will be amazed!

The puzzle box involves two unlocking steps: First, the hand of the man in the armchair with the remote control must be lifted so that the front screen of the TV falls down. Next, the Formula 1 car must be turned to the left so that the drawer, which is pre-tensioned by a rubber, opens.
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Step 1: How it works!
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Let's start with the puzzle box itself to really catch your attention. This GIF (open the picture to see the movement) shows how it works! Pretty simple, yet quite astonishing! Just lift the lazy man's arm with the remote control and then let the formula 1 car race, so that the drawer pretensioned via a rubber band opens. 

How to do it? Follow the following steps and create a great gift for a lazy TV watching friend!

Step 2: Designing the box
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I use the free software Sketchup Make to create a 3D design of my idea. Each individual part is created as a group and can later be projected onto a flat surface to export a DXF.

For the mechanism of such a puzzle box, I always think about where the box should open and where I need a latch. 

Step 3: Import and edit dxf in XTool Creative Space
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Setting 1
Process Method
Laser Cut
Process Material
3mm MDF Board
Power(%) or Cut Pressure(g)
100
Pass
2
Speed(mm/s)
4
Setting 2
Process Method
Vector Laser Engrave
Process Material
3mm MDF Board
Power(%) or Cut Pressure(g)
80
Speed(mm/s)
120
Lines per cm
120

In the next step, I export the dxf from Sketchup and import it into Xtool Creative Space. Here you can edit it as you wish. In particular, lettering can be added to the lid. Figure 2 shows how the lettering can be customized. The text has been translated from German (see cover image) into English for the design file.

The next step is to cut the file with the specified data and engrave the text. I use my Xtool M2 for this.

Step 4: Assembly 1
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This step is the most difficult:

1. first assemble the TV and then insert it into the base platform with the many individual cut-outs. It is best to use superglue to join the individual parts together as shown in the picture!

2. make sure that the arm with the Formula 1 car can be easily turned back and forth. Be careful not to throw away the round cut-out parts! These are needed for the joint. You may need to help with a file to ensure that everything can move freely. The front screen of the TV must also be able to move freely up and down so that it can fall down under its own weight.

3 This picture shows where the TV must be inserted into the plate.

4 Next, the armchair is assembled. The individual parts can be put together, but some of them should be reinforced with superglue.

5. in this picture, where the long individual parts still need to be glued in to create the curves of the armchair is marked in red.

Step 5: Assembly 2
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6 Next, the figure is glued together as shown in this picture. In total there are 7 fixed layers (6 symmetrical + left arm) and one movable one, the right arm. This is only glued to the round part of the penultimate side piece (take care) so that it can still rotate freely around this axis (see red arrow)

7. the figure is then placed on the chair so that the arm can be inserted into the slot with the extension pointing downwards (see red arrow). After this assembly, it must still be possible to move the hand with the glued-in remote control up and down. The small stool for the feet should also be assembled before the final installation on the base plate.

8. a sliding mechanism is then installed underneath the base plate. In the middle, a part is firmly attached to the plate from below, in which the elongated part can then move back and forth. The downwardly extended arm is inserted here on the one hand and the small pin shown on the television on the other to allow the front screen to fall down.

9. the Formula 1 car lifts back the drawer at the end, which is assembled in this step as shown in the picture. The smaller of the two side parts, which can be rounded off at the corners, is glued on where the red marking is in the picture. However, this is best done at the very end, when the rest is assembled and the drawer is in the box.

10. here you can see how the box is put together at the end. At the bottom is the bottom plate, then the two inner walls, between which the drawer is guided, and then the base plate with the armchair and TV. The larger of the two side panels with the corners that can be bent round then goes around the outside.

 

Have fun with the build!

Design Files
puzzle_box_tv.xcs
puzzle_box_tv2.xcs
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