Project 0050

Rev:08/20/13
Designed by:
Ritchie Kinmont
Project #50 Page 1/29

Sonic Crossbow
Sonic Crossbow
About this project:
The Sonic Crossbow is a lot of fun for kids ages 5 to 95. This little crossbow is fired
by pulling down on the clothespin lever which releases the bowstring. The crossbow
design incorporates two handy bolt clips to store extra bolts below the bow. This
project also includes a target for sharpening your crossbow skills
Cock the
bowstring, load
a crossbow
bolt, take aim,
and let the bolt
fly!
2013 SonicDad Enterprises All rights reserved

Sonic Crossbow
Rev:08/20/13
Whats it made of?

The Sonic Crossbow frame and bow are made from 1 gallon paint stir sticks, two elastic
hairbands for the bowstring, a shoelace to cover the grip, mini hair clips and mini
popsicle sticks for the bolt clips, and a clothespin for the firing mechanism.
Wood clothespin
Elastic hairband
Shoelace
Adhesive-backed craft
foam sheet
Mini popsicle sticks
1 gallon paint
stir sticks
Mini hair clips


Sonic Crossbow
Rev:08/20/13
Whats it made of?

The Sonic Crossbow bolts are made from hardwood dowels for the shafts, craft foam
for the fins, and foam ear plugs for the tips.
Hardwood dowel
Craft foam
Foam ear plugs

Sonic Crossbow
Rev:08/20/13
Whats it made of?

The crossbow target is made from a full sheet printer label, a piece of poster board,
and a 1 gallon paint stir stick.
Poster board
Ink jet labels
1 gallon paint stir stick

Sonic Crossbow
Rev:08/20/13
Project Construction
3.0 HRS
LEVEL 5
$10.00
Check out my way cool Sonic Dad

gauges for project difficulty,
time, and cost. Cost of this
project depends on how many
items you have on hand. If you
purchase all items new, cost will be
higher than the approximate cost
shown.
SHOPPING LIST
Quantity
Item needed
Where to find it
See Figure
1 gallon paint stir stick (Home Depot stir stick is recommended, see pg. 29 )
Home Depot, hardware store, paint store
Page 2, 4, 29, A,B
1/4 diameter hardwood dowel (approx. 32 required)
Home Depot, discount retail store
Page 3, S, U
Wood clothes pin
Wal-Mart, discount retail store
Page 2, D, E
Mini popsicle sticks (see pg. 29 for dimensions)
Wal-Mart, craft store
Page 2, 29, L, V
Hair elastic band (approx. 6 diameter X 1/4 wide, X 1/8 thick )
Page 2, II, JJ
Mini hair clips (small enough to clamp around an 1/4 dowel)
Wal-Mart, craft store
Page 2, CC, DD
Flat shoelace (black or the color of your choice, 72 long)
Page 2, X, Y
Avery full sheet ink-jet printer labels #48165
Wal-Mart, discount retail store, office supply store Page 4, GG, OO
Piece of poster board or other thin cardboard 4 x 4
1 pkg
Page 4, UU
1 sheet
Adhesive-backed foam sheet, black or the color of your choice (we recommend Craft store, online store
using only Foamies brand for best adhesion)
Page 2, GG, HH
1 sheet
2mm thick non-adhesive backed craft foam (orange or the color of your choice) Craft store
Page 3, OO, PP
Foam ear plugs (orange or the color of your choice)
Page 3, RR, SS
1 pkg
Wal-Mart (gun or pharmacy section)

Sonic Crossbow
Rev:08/20/13
SUPPLIES AND TOOLS NEEDED

Item needed
Where to find it
High temp hot glue gun and glue sticks
Discount retail store, home improvement store, craft store
Scissors
Discount retail store, home improvement store
Wood saw (for cutting paint stir sticks, clothespin, and wood dowel)
Ball point pen or pencil for marking
Discount retail store
100, 150, and 400 grit sand paper
12 ruler
Krylon Cristal Clear satin (or equivalent) spray paint
X-acto knife with sharp #11 blades
Step 1
Use template to
mark cut lines
fig. A
Print the cutting templates from pages 23 - 25 on

regular printer paper. Lay the template sheets on
your work surface, then lay the stir stick on top
for marking. Use a pen or pencil to mark the cut
lines on each piece to be cut. Mark and cut the
clothes pin as shown on the template. (fig. A)
Use 100 and 150

grit sand paper to
sand edges smooth
Step 2
Use 100 and then 150 grit sandpaper to sand all
the cut edges smooth. You may also want to
remove the printing on the stir sticks for a
better appearance. Sand the printed surface
with 100 then 150 grit sand paper. (fig. B)
fig. B
Mark center
location lines
Step 3
Cut the width of the bow support piece, then mark
and cut the angles. After sanding smooth, use the
template to mark the center location lines as
shown. (fig. C)
fig. C

Sonic Crossbow
Rev:08/20/13
Step 4
Cut square
corner on top
clothespin jaw
After cutting and sanding the clothespin,

carefuly remove the top jaw. On a suitable
surface, use an X-acto knife with sharp blade to
cut a square corner on the front side of the
semi-circular feature as shown. This will keep the
bowstring from slipping out of the clothespin
before firing the crossbow. (fig. D)
fig. D
Applying a little glue on

each side of the spring
will keep the clothespin
from coming apart . . .
firing mechanism failure,
bummer! After gluing, the
clothespin may feel a bit
stiff. Thats ok the
stiffness will help keep
the bowstring in place
before you fire.
Step 5
Use your fingers to spread the clothespin apart
as shown. Apply a small bead of glue on each side
of the spring and let the clothespin relax. Apply
glue in each spring slot to secure the spring to
the clothespin. Wipe away any excess glue. (fig. E)
Spread clothespin
apart
fig. E
When you are finished

cutting and sanding, lay
all the parts out to make
sure you have cut every
piece you will need. Just
compare to this picture
to double check. These
pieces are for the
crossbow, so if you are
also making the target,
you will need the two
pieces from page 26.
Apply glue on
each side of
spring
Apply glue in each
slot to secure spring
All pieces required
Step 6
When you have cut and sanded all the pieces
required for this project, lay them out to double
check your pieces and quantities. You should have
all the pieces shown. The pieces shown are for
constructing the crossbow; if you will be building
the target, please refer to sheet 26 for the
pieces required. (fig. F)
fig. F

Sonic Crossbow
Rev:08/20/13
Step 7
Print the frame assembly template sheet from
page 27 on regular printer paper and lay it on
your work surface. Use high-temp hot glue to
attach all pieces in this project. Using the
template for location, attach the frame center
piece to one of the outer rails as shown. Be sure
to line the pieces up carefully with the template.
(fig. G)
Use template to
attach frame center
to side rail
Take your time when

assembling these first
two pieces. Its important
to get this alignment
right so the rest of your
crossbow will fit together
nicely. I always like to
test fit the pieces
together before gluing
because you only get one
shot at it! The nice thing
about hot glue is it sets
up fast, the bad thing
about hot glue is it sets
up fast! So be sure you
know how the pieces go
together before you glue.
fig. G
Step 8
Attach the inner grip piece in the position
shown. (fig. H)
fig. H
Attach second rail

piece lined up with
the first
Attach inner grip

piece
Step 9
fig. I
Attach the second rail piece as shown. Be sure

to line the edges up with the first rail piece.
(fig. I)

Sonic Crossbow
Rev:08/20/13
Step 10
Attach the two outer grip pieces in the position
shown. (fig. J)
fig. J
fig. K
Attach two outer
grip pieces
Attach modified
clothespin
Step 11
Attach the modified clothespin in the position
shown. (fig. K)
Attach mini popsicle

stick flush with rail
on each side
These little popsicle

sticks are great at
guiding the bowstring as
it snaps out of the
clothespin. Locating these
little guys is important.
Glue them flush with the
top of the rail and flush
with the half-round
feature in the clothespin
lower jaw. Bowstring
guidance . . . cool!
Line up flush with

clothespin opening
fig. L
Step 12
Attach a mini popsicle stick on each side of the
frame to serve as a bowstring guide. Locate the
guides flush with the tops of the rails and flush
with the opening in the clothespin lower jaw as
shown. (fig. L)

Sonic Crossbow
Rev:08/20/13
Step 13
Sand front and
top smooth
Use a piece of 150, then 400 grit sandpaper to

sand the rails smooth to prevent the fabric
sheath on the bowstring from snagging on the
wood fibers. Sand the top and front angled
surfaces of the rails completely smooth and
rounded as shown. (fig. M)
Attach bow
support
fig. M
Step 14
Attach the bow support to the frame using the
center markings for alignment as shown. As the
glue begins to cool, check the support to be sure
it is perpendicular to the frame. (fig. N)
fig. N
Step 15
Attach each bow to the support and frame in the
positions shown. (fig. O)
fig. P
Attach support
block on each side
Attach each bow to

the support and frame
fig. O
Step 16
Attach a support block on each side of the frame
in the position shown. (fig. P)

Sonic Crossbow
Rev:08/20/13
Step 17
Add a bead of glue in the areas shown to
reinforce the bow and frame. Use a paper towel
to wipe away any excess glue. (fig. Q)
Apply glue to reinforce

bow and frame
Attach mini popsicle

stick on each side
fig. Q
Step 18
fig. R
Attach a mini popsicle stick centered below each

side of the bow support as shown. Align the
popsicle sticks parallel to the frame. (fig. R)
Step 19
10
Mark and cut three 10 long pieces of 1/4 wood

dowel for bolt construction in a later step. Sand
the cut edges with 150 grit sandpaper. Sand the
surface of the dowels smooth using 400 grit
sandpaper. (fig. S)
Sand smooth
fig. S
fig. T
Step 20
To give your Sonic Crossbow a durable finish,

sand all visible surfaces with 150, then 400 grit
sandpaper. Thoroughly clean all surfaces and
apply one coat of Krylon Crystal Clear satin or
equivalent. (fig. T)

Sonic Crossbow
Rev:08/20/13
Step 21
Lightly sand all surfaces again with 400 grit
sandpaper, and apply a final coat of clear. After
the final coat is dry, sand again with 400 grit until
smooth. Be sure the top and front surfaces of the
rails are smooth. (fig. U)
fig. W
Final sand
smooth
Step 22
fig. U
Step 23
Apply one coat of Krylon Crystal Clear satin or
equivalent on two mini popsicle sticks. Set them
aside for a later step. (fig. W)
Thoroughly clean all surfaces and apply one coat

of Krylon Crystal Clear satin or equivalent on all
three bolt dowels. Lightly sand again with 400
grit sandpaper, and apply a final coat of clear.
After the final coat is dry, sand again with 400
grit until smooth. Set the dowels aside for a later
step. (fig. V)
fig. V
Attach shoelace
end to grip
Step 24
fig. X
Attach the end of a flat 72 long shoelace in the

location shown using high-temp hot glue. (fig. X)
Rev:08/20/13

Sonic Crossbow
Step 25
Carefully wrap the shoelace around on itself

three times, gluing each wrap to the wrap below.
On the third wrap, bring the lace across as
shown and glue to the grip. (fig. Y)
Wrap around
bottom three
times then onto
grip
Tightly wrap
around grip
fig. Y
fig. Z
Step 26
Tightly wrap the shoe lace around the grip with
each wrap tightly against the previous wrap.
(fig. Z)
Step 27
Continue to tightly wrap until the wrap is even
with the bottom of the frame as shown. Glue
this final wrap to the grip to keep all the wraps
tight. (fig. AA)
Wrap until
even with
bottom of
frame
Wrap three times

then cut and glue
end at back
fig. AA
Step 28
fig. BB
Finish by wrapping around three times, gluing

each wrap to the wrap below. Cut the shoelace
at the back on the third wrap. Glue the loose
end down as shown. (fig. BB)

Sonic Crossbow
Rev:08/20/13
Step 29
Clip two mini hair clips onto a bolt dowel as
shown. Hold the clips next to the mini popsicle
stick on the frame. Adjust the position of the
clips until they are positioned at each end of the
popsicle stick as shown. (fig. CC)
Space clips even with

popsicle stick ends
fig. CC
Attach clips to
popsicle stick
fig. DD
Step 30
Apply a bead of glue on each end of the first
popsicle stick. Carefully attach the clips to the
popsicle stick as shown. As the glue cools check
to make sure the dowel is parallel to the frame.
Looking at the side, be sure the dowel is parallel
with the bottom edge of the frame. (fig. DD)
Step 31
Attach two more clips to the other side following
the same steps. (fig. EE)
Attach popsicle stick

across clips
Attach second
set of clips
fig. EE
Step 32
fig. FF
Attach the two popsicle sticks from step 23

across each set of clips as shown. Remove the
bolt dowels and set them aside for a later step.
(fig. FF)
Rev:08/20/13

Sonic Crossbow
Step 33
Print the cutting application templates from

page 28 on a full sheet printer label. Using a
sharp pair of scissors, roughly cut around the
forend grip template leaving about 1/4 margin.
Peal the backing and apply the cutting template
to the backing side of a piece of adhesivebacked craft foam. Carefully cut out the forend
piece by cutting on the template cut lines as
shown. (fig. GG)
Attach forend
grip pad and fold
over other side
fig. GG
Attach cutting
template and cut
out foam pad
Step 34
Remove the backing on the foam and carefully
locate the forend pad flush against the side rail
in the position shown. Press the edge of the
foam piece down firmly all the way along.
Carefully fold the pad over onto the other side
of the frame. Firmly press the pad down on both
sides of the frame. (fig. HH)
fig. HH
Cut on glue
joint
Step 35
Locate the glue joint on the hairband. Cut the band
in the center of the glue joint as shown. Cut two
hairbands. (fig. LL)
10
fig. II
Step 36
Tie knots 10
apart
fig. JJ
Hold the two cut hairbands together and tie a

knot in one end. Carefully tie a second knot 10
from the first. Be sure to remove any twists in
the hairbands before tying the second knot.
(fig. II)

Sonic Crossbow
Rev:08/20/13
Step 37
Install the bowstring into the slots on each end of
the bow with the knots on the front side as shown.
Test the bowstring by pulling the strings back as
shown. The strings should stop stretching in about
the middle of the clothespin. Make adjustments in
the knot positions if necessary. Trim off the extra
bowstring length with scissors. (fig. JJ)
Trim after testing
Test bowstring
fig. KK
To get the best

performance out of your
crossbow, youll want to
test your string for the
correct tension. Its easy,
just pull the string back
until it stops stretching.
For the best results you
want the string to stop
stretching in the middle
of the clothespin. You
may have to adjust the
knot position in the string
to get the right tension,
but you can do it!
Place top
hairband on lower
Step 38
Pull the top hairband back and hold it out of the
way. Carefully apply a small bead of glue in the
center of the lower hairband about 1 1/2 long as
shown. (fig. KK)
Apply glue on lower

hairband
fig. MM
fig. LL
Step 39
Working quickly while the glue is still hot,
carefully place the top hairband on top of the
lower to secure them together. (fig. MM)

Sonic Crossbow
Rev:08/20/13
Making Crossbow Bolts

Mark fin location
lines
Step 1
Use the layout drawing to mark the fin location
lines on the three crossbow bolt dowels as
shown. (fig. NN)
fig. NN
Cut fins out and

remove label
Step 2
Roughly Cut around the fin templates and peel off
the backing. Its helpful to remove some of the
tackiness of the label by repeatedly touching the
adhesive with you fingers. This will make it easier
to remove the cutting templates from the foam
after cutting. Apply the label to a non-adhesive
backed foam sheet. Cut out each fin and remove
the label. (fig. OO)
fig. OO
The adhesive on the

label cutting
templates can be
pretty sticky! Getting
the label off of the
foam after cutting
can be a chore! I like
to take some of the
tackiness off of the
label with my fingers
before sticking it to
the foam. That way
pealing the template
off after cutting will
be much easer . . .
way cool!
Step 3
Apply a bead of high-temp hot glue on a fin as
shown. (fig. PP)
Apply bead
of glue
fig. PP

Sonic Crossbow
Rev:08/20/13
Step 4
Attach fin on location
marking
Working quickly while the glue is still hot, attach

the fin on a fin location line. Be sure the fin is
aligned straight down the axis of the dowel.
(fig. QQ)
Apply glue in center
fig. QQ
Step 5
fig. RR
Apply glue in the center on the back surface of a

foam ear plug as shown. (fig. RR)
Step 6
Working quickly while the glue is still hot, place
the end of the dowel in the center of the glue as
shown. (fig. SS)
Place dowel in center

of glue
Straighten tip as
glue cools
fig. SS
Step 7
While the glue is still hot, turn the bolt over as
shown. Use your finger to gently align the foam
tip straight with the bolt shaft. Rotate the shaft
a few time while straightening the tip. (fig. TT)
fig. TT

Sonic Crossbow
Rev:08/20/13
Target Construction
Step 1
Apply target decal

to cardboard
Roughly cut around the target decal, peal the

backing and apply to a piece of poster board or
thin cardboard. (fig. UU)
Cut target out
fig. VV
fig. UU
Glue base to
upright
Step 3
Use high-tem hot glue to attach the target to
the support in the location shown. (fig. WW)
Step 2
Use the target cutting template on page 26 to
mark cut locations on a 1 gallon stir stick. Cut
the target support and base; sand edges smooth.
Glue the pieces together as shown. (fig. VV)
Attach target to
support
fig. WW

Sonic Crossbow
Rev:08/20/13
Loading Your Sonic Crossbow
To cock your crossbow,

pull back the string
with two fingers like
this. Use your other
hand to open the
clothespin. Insert the
bowstring into the
clothespin and let it
clamp around it. Gently
release the tension
with your fingers and
your crossbow is
cocked and ready for a
bolt to be loaded. . .
cool!
Now load a bolt with one fin

down inside the grove like
this. Slide the bolt all the
way back against the
clothespin. You are now
cocked and loaded!

Sonic Crossbow
Rev:08/20/13
Firing Your Sonic Crossbow
To fire your cross bow,

first take aim at your
target. Then press down on
the clothespin to release
the bowstring and Bamo!
Your crossbow bolt is
screaming across the sky!
Notice to Airmen:
The Sonic Crossbow is
a lot of fun to use, but
if misused it can also
cause serious injury.
Never point or fire
the crossbow at people
or animals. Always
point the crossbow
away from your face
when loading the bolts.
Always shoot at
inanimate targets, like
the one provided in
this project. Please use
the Sonic Crossbow
safely, and have fun!
Sonic Crossbow
Frame Layout Drawings ( scale)
(for reference use)
Side View
Top View

Sonic Crossbow
Rev:08/20/13
Sonic Crossbow
Cutting Templates
(print full scale on printer paper)
Bow Qty. 2
(1 gallon stir stick)
Side Rail Qty. 2

Bow Support Qty. 1


Sonic Crossbow
Rev:08/20/13
Sonic Crossbow
Cutting Templates
Firing Mechanism Qty. 1

(wood clothespin)
Inner Grip Qty. 1

Outer Grip Qty. 2


Sonic Crossbow
Rev:08/20/13
Sonic Crossbow
Cutting Templates

Sonic Crossbow
Rev:08/20/13
Frame Center Qty. 1

Support Block Qty. 2

Sonic Crossbow
Cutting Templates
Target base Qty. 1

Target support Qty. 1


Sonic Crossbow
Rev:08/20/13
Sonic Crossbow
Assembly Templates

Sonic Crossbow
Rev:08/20/13
Fin Location Template
Frame Assembly Template
Sonic Crossbow
Fin Templates/Forend Grip
Template/Target Decal
(print full scale on full sheet printer label)

Bolt Fin
(orange NON adhesive backed craft foam)
Forend Grip
(black adhesive backed craft foam)
Target Decal
(poster board see fig. UU)

Sonic Crossbow
Rev:08/20/13
Sonic Crossbow
Key Components Dimensions

Sonic Crossbow
Rev:08/20/13
Please Note: These dimensional drawings are offered as a reference in

finding a suitable replacement for items not readily available in all countries.
Mini Popsicle Stick Dimensions
2 9/16
(65 mm)
3/8
(9.5 mm)
3/32
(2.4 mm)
One Gallon Paint Stir Stick Dimensions
(as found in Home Depot in the US)
12
(304.8 mm)
1 1/16
(27 mm)
1/8
(3.2 mm)

Project 0050

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Rev:08/20/13

Project #50 Page 1/29

2013 SonicDad Enterprises All rights reserved

Project #50 Page 2/29

Whats it made of?

Mini popsicle sticks

Mini hair clips

Project #50 Page 3/29

Whats it made of?

Foam ear plugs

2013 SonicDad Enterprises All rights reserved

Project #50 Page 4/29

Whats it made of?

Ink jet labels

1 gallon paint stir stick

2012 SonicDad Enterprises All rights reserved

Project #50 Page 5/29

Check out my way cool Sonic Dad

Home Depot, hardware store, paint store

Page 2, 4, 29, A,B

1/4 diameter hardwood dowel (approx. 32 required)

Home Depot, discount retail store

Wood clothes pin

Wal-Mart, discount retail store

Mini popsicle sticks (see pg. 29 for dimensions)

Wal-Mart, craft store

Hair elastic band (approx. 6 diameter X 1/4 wide, X 1/8 thick )

Wal-Mart, discount retail store

Mini hair clips (small enough to clamp around an 1/4 dowel)

Wal-Mart, craft store

Flat shoelace (black or the color of your choice, 72 long)

Wal-Mart, discount retail store

Avery full sheet ink-jet printer labels #48165

Wal-Mart, discount retail store, office supply store Page 4, GG, OO

Piece of poster board or other thin cardboard 4 x 4

Wal-Mart, discount retail store

Foam ear plugs (orange or the color of your choice)

Wal-Mart (gun or pharmacy section)

2013 SonicDad Enterprises All rights reserved

Project #50 Page 6/29

SUPPLIES AND TOOLS NEEDED

High temp hot glue gun and glue sticks

Discount retail store, home improvement store, craft store

Discount retail store, home improvement store

Discount retail store, home improvement store

Ball point pen or pencil for marking

Discount retail store

100, 150, and 400 grit sand paper

Discount retail store, home improvement store

Discount retail store, home improvement store

Krylon Cristal Clear satin (or equivalent) spray paint

Discount retail store, home improvement store

X-acto knife with sharp #11 blades

Discount retail store, home improvement store

Print the cutting templates from pages 23 - 25 on

Use 100 and 150

Project #50 Page 7/29

After cutting and sanding the clothespin,

Applying a little glue on

When you are finished

All pieces required

Project #50 Page 8/29

Take your time when

Attach second rail