Please note; this model is currently unfinished, in particular the details on the head are missing.
 
The model should look something like this, be fairly flexible and float like a rock.

*** *** *** ** ** * * ** ** *** The Amazing Aluminium Tuna *** ** ** * * ** ** *** *** ***

This is not as complicated as the model the MIT folk have made, you won't need a degree in robot science
But you will need time and the following:
 
Minimum Construction Requirements:
* 3mm thick, Sheet Aluminium
* 1mm thick, Brass Sheet (A5 size)
* 1mm thick, Copper Sheet (A5 size)
* Many small washers or bike inner-tube
* Cycle cable to go through washers
* nipple-less cable clamps (?)
* Hack-saw & Blades
* Drill with 2mm Bit
* Clamp & WorkTop
* Metal File
 
Recomended Construction Requirements:
* 3mm thick, Sheet Aluminium
* 1mm thick, Brass Sheet (A4 size)
* 1mm thick, Copper Sheet (A5 size)
* Many small washers or bike inner-tube
* Cycle cable to go through washers
* nipple-less cable clamps (?)
* Bench Jig-saw & Blades
* Drill with 2mm Bit
* Soldering iron
* Vice & Workbench
* Metal File
 
You could use any stiff material that can be cut and drilled. I used aluminium because it's easy to file.
If you're thinking of making this as a present for some-one make sure you love them very much.
Instructions:
  1. Down-load and print the 4 template sheets below. (make sure they are all in the same size)
  2. Cut and stick the rib templates onto the aluminium sheet and drill the cable holes for each rib.
  3. Cut out the aluminium ribs, losely thread them onto the cables with spacer washers.
  4. Decide at this stage how many spacing washers you need between ribs for flexibility.
  5. File the ribs roughly to shape.
  6. Cut and stick the fin templates (with their tabs) onto the brass sheet and cut out.
  7. Mark, on the relevant ribs, where the fin tabs need slots to be cut.
  8. Cut the slots on the fin holding ribs, with a notch to enable the fin tab to lock in place.
  9. Thread the cable onto the tail-fin holder, fold and solder the tail-fin into place.
  10. Thread all the ribs, washers and fins.
  11. At this stage, holding the cables taught you should have an idea what bits need further filing.
  12. Cut out the Head, using the head template and bend to shape.
  13. Work out a way of attaching the head to the body.
  14. Tighten and hold the body on the cables using the cable clamps.
   
  NB. You could cut out rubber discs, cut from an inner-tube, to use as rib spacers instead of using washers.

See Detailed photos

Click on the template format you would like to use. (self extracting files - save to a new folder) Turbo Cad for Windows Drawing eXchange AutoCAD Native
 
Alternatively get self extracting files in BMP format but remember to keep all scales consistent when printing

Is making this a real pain under the gills ? Then e-mail: stagbeetle@stagbeetle.plus.com for sympathy.

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