Lay out a yardstick on your work space. Note the approximate length of your bridge. Lay your yardstick crosswise to note the width of your bridge. Estimate the amount of popsicle sticks based on these dimensions, and the size of popsicle stick you decide on using.
Popsicle sticks Hot glue gun (and glue) Large piece of cardboard or construction paper Paper (for designing) Pencil Scissors or shears (for cutting popsicle sticks) Yardstick or ruler
For the purposes of providing a guided example, the following model bridge will be built following the classic Warren truss bridge structure. [2] X Research source
Crosswise floor beams and struts. A deck, that forms the walkway or road of the bridge. Longways laying stringer beams beneath the deck. An external frame, composed of squares divided into triangles for better integrity. Cross bracing forming an X along the top sections of the bridge. Sway bracing beneath the top crosswise struts. [4] X Research source
Lay out four rows of popsicle sticks with each row being three sticks wide. Each row should be equal in length. Cut four popsicle sticks in half. Place each of the halved popsicle sticks at both ends of each of the truss beams, in the middle position of the three-wide popsicle sticks. The component three-wide popsicle sticks of each truss will be glued together to form a truss three sticks thick.
Hot glue dries very quickly! For best results, press and/or clamp your popsicle sticks together as soon as the glue has been applied. Press the popsicle sticks together and apply firm pressure so your trusses are securely glued.
If, when you touch your glued truss, the bond feels weak, tacky, or loose, allow the glue to dry for another 15 minutes.
Another way to think of this: each line of the W pattern that will connect two trusses together represents two popsicle sticks laid side by side. The more bracing you have, the stronger your bridge will be. However, too many popsicle sticks might make it difficult to see anything move across the deck of your bridge.
Position your popsicle sticks along the truss beams before gluing to verify the final structure of the wall truss. Use hot glue, or another suitable glue, to adhere the popsicle stick cross braces to the truss beams. Wait sufficient time until the glue you are using sets.
The distance between your crosswise popsicle stick deck will determine the width of your bridge deck. Be sure that all of your popsicle sticks are even, otherwise the deck leading over your bridge will look irregular.
Once your deck supports are in position, use your hot glue gun or some other suitable glue to fasten your supports in place. If you are using wood glue or general purpose glue, allow some time for the glue to dry before handling the deck.
Multiply the width of your truss measurement by two to account for the width of both trusses and then add the width of the deck. Cut three or four popsicle sticks to this length. If your popsicle sticks are too short, make a longer one. Cut two sticks and, with glue, join each by attaching another stick to the bottom for support.
Secure the first two deck cradle beams within the cross braces of the trusses at both ends of the bridge. Use your glue to attach your cradle beams on the truss beam. Hold the glue firmly until it sets and is well bonded to the truss.
Try to move quickly during this step, especially if using hot glue. It would be unfortunate if the glue dried before you were able to lay the deck into place.
Equal distance spacing will give the appearance of the real thing.
