We'd like to send out a big Thank You!! to all supporters and to Kickstarter for this project opportunity. If we can figure out a way to make Pucks without funding, we'll likely offer them at RollingWaveDesign on Etsy. Stay tuned to www.PuckOn.com!
-The Puck Team
WHAT & WHY
The Puck holds 3/4 inch PVC pipe to a flat surface. It makes projects look good for your house or business and it's strong! The Puck
allows you to make many creative wall or surface mounted projects using inexpensive PVC
pipe and fittings available from any hardware store. It’s fun, easy, and creative! Backing this project allows the Puck to get molded to ‘kickstart’ production and to make it available for your great projects!
Check out www.puckon.com to see lots of great project ideas on our Facebook page.
TIME IS RUNNING OUT! CHECK OUT OUR REWARDS SECTION BELOW: YOU CAN NOW RECEIVE 1 OR 2 EXTRA PUCKS WITH EVERY PLEDGE IF WE REACH OUR GOAL!!!
HELP SUPPORT LOCAL BUSINESSES AND MAKE GREAT PROJECTS! PLEDGE TODAY!
There’s something about pressing parts together to make fun
and creative shapes--maybe it comes from playing with Tinkertoys, Legos or some
other primordial passion. The Puck opens the door to hundreds of fun and practical project possibilities--it’s
up to your imagination! And it seems to work for just about all ages: my three
year old son finds it equally as fun to piece together projects as I do.
A simple, easy to make skateboard rack, expandable to any number of boards. This particular design allows you to display the bottom of the board. Make it how YOU want it with PVC pipe and the Puck! Check out the video: https://www.youtube.com/watch?v=g6_dHyuKjR0
The Puck is being offered in two gloss finish colors for this Kickstarter project: white and black. A white Puck can be easily painted
with a color of your choice using plastic spray paint. The Puck measures just a
bit over 3 inches in diameter by1.125 inches
HOW IT WORKS
PVC pipe and parts to be used
with the Puck are easy to cut. You can easily paint it too. The pipe and connectors are
inexpensive and available from all home improvement centers.If you envision a large project requiring
lots of colored pipe and colored fittings, it’s possible to purchase colored
‘furniture grade’ PVC pipe from several sources in the US (C & S Plastics
has nice quality colored PVC pipe and fittings).
The PVC pipe and Puck fit
together snugly and in most cases won’t even require any glue. The screw holes
are sized large enough to fit most drywall screws.
How to make a simple 3 board surf rack:
I use Schedule 40 PVC pipe for all my projects, which has so far proven plenty strong. However, each application will require its own testing to ensure the strength is sufficient. For example, the surfboard rack works well with shortboards but might not support heavier longboards with just two rack brackets. The photos below show a simple weight test of a small PVC shelf. The Puck I used was a wood prototype. We expect the plastic molded Puck to be at least as strong. I ran out of bricks but it would have held more:
FUNDING & PRODUCTION
We need your help so we can begin production. The CAD design files are complete, we have working prototypes that we have tested, and we have a local molding company ready to go into production. We want it made locally so we can monitor the quality and ensure we get a quality part that works and lasts for many years. But having a mold made is costly, so that’s where we need your help.
We decided to avoid making the Puck out of PVC plastic since PVC is currently one of the more difficult plastics to recycle, yet it is really the only available material from all our hardware stores for the pipe and fittings. We chose to go with ABS or a reinforced polycarbonate, which are more easily recyclable. We will run a test of both plastics after the mold is complete to determine the optimal choice of material.
Shipping will begin approximately five to six weeks from the date of funding. The molding company assured us a lead time of about 3-4 weeks for tooling and a finished product. We are adding several weeks extra for any delays and to allow for packaging and shipping.
UPDATE 1-20-14!!!!! WE WERE OFFERING RED PUCKS BUT YOUR FEEDBACK AND SUPPORT TOLD US YOU WANT WHITE OR BLACK! SINCE RED PLASTIC COSTS MORE, WE ARE PASSING THE SAVINGS ON TO ALL BACKERS OF $20 OR $35! YOU WILL RECEIVE 1 EXTRA PUCK FOR A TOTAL OF 3 PUCKS FOR A $20 PLEDGE. YOU WILL RECEIVE 2 EXTRA PUCKS FOR A TOTAL OF 6 PUCKS ON EVERY $35 PLEDGE IF WE REACH OUR GOAL!!!!!
• The Puck will be available in two colors: White and Black.
• A set of two Pucks is enough to build a towel rack or to do several small projects.
• A set of four Pucks is enough to build a surf rack or several towel racks or ???
• Note: White Pucks will be all one color—inside and out. The above photo shows a painted prototype that was made using black plastic. Actual Pucks will be a single color.
The Puck team includes myself, Christopher Zervas, and Liz Brown, a fellow maker from the MakerPlace, a local maker cooperative workshop in San Diego. Liz saw the potential in the Puck and has the business experience and cyberworld knowledge for social media that will help guide the project. She’s also a super-maker who’s not afraid to dive into a project using anything from a table saw to CNC router!
I started this project about a year ago because I couldn’t find a good way to mount PVC pipe firmly to a wall that also looked good. It started when I wanted to make a simple, custom sized towel rack and other household fixtures using PVC pipe because it’s so easy to work with, inexpensive and easily colored with plastic spray paint. Most towel holders come in a limited set of standard sizes and a very limited range of colors. The industry is generally pretty stagnant. I found schedule 40 PVC pipe to be strong yet easy to cut and piece together with a myriad of fittings—the big problem was finding an effective method of attaching the pipe to a wall.
That’s when I began to work on wall flange prototypes at the MakerPlace, which eventually led to the Puck. I started with wood and discovered the Puck concept worked very well. But I found problems with using wood: it was difficult to get consistent results since the pipe cavity needed to be a very specific diameter--to a thousandth of an inch and with a very slight taper in order to hold the PVC pipe with just the right amount of friction tension. A perfectly snug fit usually allows making projects without glue—the friction fit is enough to hold it all in place yet allows disassembly if needed (reuse/recycle!). After consideration of practicality, function and consistency, I decided the Puck would be best injection molded.
To learn the ins and outs of product development I attended monthly inventor’s meetings with a local inventor’s forum in San Diego, where professionals from many fields shared experiences and knowledge of project development. Many entrepreneurs shared discouraging stories of having parts made overseas where unless one was a large company with representatives literally watching every step of the process at the factory in order to ensure consistent quality standards, the results were often disappointing and shipping costs considerable. The stories encouraged me to think locally. So I started looking locally and found a great locally owned company that’s been in business for over 30 years and whose production manager, Martin Quinn, has personally helped me along the development of the Puck. We are able to communicate easily, I get great customer service and I get to support our local economy. It was a pleasure to be able to go back and forth with the prototype, my CAD designer and the molding company to refine the design and ensure we had an excellent product. I’m also confident we can get the best quality part by keeping it local because we can more easily test, refine and make the necessary iterations as needed.
Thank you for taking the time to consider our project and we truly appreciate your support! If you are a backer and build an interesting project, we would like to showcase it on our Puck Facebook page to share with everyone. Just email us a photo of the project and we'll post it. Going to www.PuckOn.com will take you directly to the Puck Facebook page.
-Chris & Liz
Risks and challenges
1. Molding shrink lines: The local molding company will do its best to mitigate shrink marks on the surface directly above thicker underside support sections of the Puck; however, there is still a chance that very slight shrink lines will occur on the surface. This is because the plastic is thicker in these sections, causing more shrinkage than where the walls are of uniform thickness. At this time we do not know how noticeable the shrink lines will be-- the molding company predicts it will be nominal. Shrink lines, if they are noticeable, will have no effect on the strength of the Puck.
2. Strength: The Puck is designed with extra thick walls and supports on the underside. The screw holes are also designed with extra thick walls to mitigate blowout from over-tightening, common when using a high torque drill-driver. However, given enough torque, any plastic will give out at some point. For this reason, we recommend seating the screws by hand to avoid breakage from too much torque.
3. Fulfillment: Since we are using a local molding company with years of experience, we feel confident we will avoid the myriad of problems often associated with overseas production, such as inconsistent quality and shipping and production delays. The latest 3D prototypes produced based off the finalized CAD design plans function as hoped—the fit is excellent and the part functions as planned, so we don’t expect any design problems at this time. If for any reason our molding company is unable to produce the part as expected, we have other molding companies that are capable of producing it.
If too much leverage on a fixture requires more stability than just a friction fit, a little dab of Super Glue or almost any other plastic glue holds it in place very well. I’ve even used hairspray for a tight fit that can be broken loose later if needed. So no need for messy and smelly PVC glue—it’s only needed to hold fluid pressure in plumbing installations. The Puck is not for plumbing installations. I actually prefer a common sealant type adhesive over Super Glue because it sets up more slowly allowing me to line up the parts better before it dries. In addition, I can break the seal with enough pressure using a pair of channel lock pliers. Super Glue sets up so fast it makes it a little hard to line up parts just right. As soon as you push the pieces together with Super Glue, it’s stuck!
Our intentions are for a high gloss finish. However, there might be differences to the level of gloss and of the shade of red illustrated in the photos of the painted prototypes. We'll do the best we can to match the colors.
We won’t know the actual retail cost of the Puck until we have completed the molding process and reached the next level. The rewards are not an indicator of the final price of the Puck. The pledge goal of this campaign is to help ‘kickstart’ the business and allow the initial production of the Puck. Subsequent order quantities and other variables will affect future pricing.
The Puck is meant to look good, yet is also designed to be very strong. Industrial pipe flanges look, well, industrial and might not fit one's design expectations. They are often quite difficult to obtain too since they are designed specifically for commercial plumbers rather than the typical DIY'er. We want The Puck to be easily available from a local hardware store or craft store.
We've been using Rust-Oleum Painter's Touch Ultra Cover, Paint + Primer with very good results (available at Home Depot for about $4 a can): easy application, smooth and very hard finish. Wiping down the PVC with a bit of acetone works well to clean and prep. Sanding before painting also works but be careful to remove ALL the dust or the small dust particles will really show up in the paint (live and learn). If you want to avoid any harsh chemicals or sanding dust, just clean it well with a household cleaner that does not leave a residue, dry it well and paint. The spray paint goes on really well and really does not require much prep.
A PVC pipe cutter available from just about any hardware store or plumbing supply store works great: no messy, dusty cuts. It just slices right through the PVC with a ratcheting mechanism. Home Depot sells them for about $13. A wood saw or chop saw works fine too but makes a lot of plastic dust. PVC is pretty soft so it won't harm wood tool blades.