The Falcon-Jacks final Upcycled Caddy Logo

Abstract[edit | edit source]

Zane Middle School is a middle school located in Eureka, California that educates 6th to 8th grade. Team Falcon-Jacks partnered with Zane Middle School to work with Elizabeth Baker, a mathematics teacher. Baker teaches 6th and 7th graders with a variety of creative tools and supplies that require organization and student accountability. Team Falcon-Jacks assignment was to create three caddies built from upcycled material for Elizabeth Baker to store school supplies and other school materials that the students utilize. Further work was focusing on the student accountability in which the caddies provide, and safety. Team Falcon-Jacks was composed of four Cal Poly Humboldt students who took Engr205 Introduction to Design during their Spring 2014 semester: Kamau Bethea, Mackenzie Danies, Diego Harrison, and Allison Tapaya.

Video[edit | edit source]

Background[edit | edit source]

The Falcon-Jacks final design is a three part caddy organization system; The Hanging Calculator Caddy, the Desktop Caddy, and the Street Sign Storage Caddy. Each of these caddies help organize specific supplies.

The Hanging Calculator Caddy[edit | edit source]

The Hanging Calculator Caddy organizes and stores all the calculators in a hanging caddy along the wall in the classroom for easy access for students. The shallow pockets also allow for the instructor to see if the students have returned their calculators or not. Each group of four students has their own Hanging Calculator Caddy. Team Falcon-Jacks built nine caddies each with different themed fabric pockets to provide unique aesthetics to each.

The Desktop Caddy[edit | edit source]

The Desktop Caddy organizes the materials the students will be utilizing that day. Each group of four students has one Desktop Caddy. Team Falcon-Jacks built nine caddies. The caddy is coated with melamine allowing the teacher to easily clean caddies with antibacterial wipes.

Street Sign Storage Caddy[edit | edit source]

The Street Sign Storage caddy stores the Desktop Caddies when they are not in use by the students. The Street Sign Storage caddy has a total of nine cubby spots. On the side of the Street Sign Storage Caddy is a smaller parking sign that is hinged to the frame which is covered with laminated paper to allow it to be used as a white board. This allows the teacher to write what supplies should remain in the desktop caddies once returned at the end of the day. The hinge gives the white board the ability to be flattened against the frame of the Street Sign Storage caddy to make for easier transportation. The Street Sign Storage caddy has two handles on the side to allow for easy transportation by two people.

Problem Statement and Criteria[edit | edit source]

Team Falcon-Jacks objective is to design a long lasting organization system that allows students to be accountable for their materials and promote upcycling to young minds. The upcycled caddies will provide the teacher with more visual access to supplies.

Table-1: Caddy Criteria
Weight Criteria Definition
9 Aesthetically Pleasing Must be visually stimulating for middle school students.
8 Portable A single person can carry the caddy.
7 Teacher Input Takes teacher less than 2 minutes to have students place materials back.
10 Student Accountability Teacher can easily tell which students do not return what materials.
8 Durability Can withstand the daily use of middle school students.
5 Maintenance Repairable with minimal input from teacher.
3 Upcycled 80% of the materials must be recycled production
6 Cost Must cost no more than $400.
10 Safety When caddy is in use, should not cause any serious injury

Description of final project[edit | edit source]

Design and Total Cost[edit | edit source]

Table-2: Caddy Costs
Caddy Item Cost per item Quantity Store Team Cost
1.5 in Corner Brace $0.99 each brace 42 each Ace $19.80
1/4 inch Plywood $24.69 per 4x4 1 4x4 Ace $24.69
1x2 wood $2.99 per 8ft 1 1x2 Ace $2.99
3/16 Cobalt Drill Bit $7.59 each 1 bit Ace $7.59
3x3/4 in Corner Brace $1.59 each brace 16 each Ace $25.44
Acrylic Paint random sizes 9 colors Donated (Allie) $0.00
Aluminum Street Signs $1.00 per pound 36 pounds Arcata Salvage $36.00
Black Thread $0.25 per stool 3 spool Humboldt Scrap $0.75
Bolts box of 100 2 Ace $6.99
Christmas Lights random sizes 1 pack Donated (Allie) $0.00
Clear Gloss Lacquer $12.99 per quart 1 quart Ace $12.99
Dish Towels $1.00 each 9 Dollar Store $9.00
Drawer Handles $2.00 per handle 2 Humboldt Scrap $4.00
Foam Paint Brush $0.99 per brush 2 brushes Ace $1.98
Hinge Kit $5.59 per kit 1 set Ace $5.49
Nuts box of 100 2 Ace $3.99
Outdoor Wood Screws 6.79 each 1 pack Ace $6.79
Particle Board random sizes 7 Donated (free wood pile) $0.00
Rivet Gun 23.99 each tool 1 tool Ace $23.99
Rivet $4.49 each rivet 1 each Ace $4.49
Sand Paper $4.59 each pack 1 pack Ace $4.59
Screws box of 100 1 Ace $7.99
Sew on Snaps $2.99 per pack 5 packs Jo-Ann Fabric $14.95
Steel Slotted Angle $13.99 each 1 Ace $13.99
Themed Cotton Fabric $6.99 per yard(on sale) 3 yards Jo-Ann Fabric $20.97
Up cycled Binder Plastic random sizes 8 sheets Donated(Allie) $0.00
Vinyl Tubing $0.35 per foot 21 feet Ace $7.25
Whiteboard random sizes 1 board Donated(Diego) $0.00
Wooden Hangers $24.99 per pack 1 pack Target $24.99
Total - - $ $313.23

Testing Results[edit | edit source]

Hanging Calculator Caddy[edit | edit source]

To test the durability and student accountability aspects of the Hanging Calculator Caddy, the caddies were filled with calculators to make sure each calculator was easily visible and the caddy was capable of holding the weight of a full set of calculators. They were also tugged on with different amounts of force to see how sturdy the snaps are. The Hanging Calculator Caddy's held up to the stress, and showed no signs of ripping or tearing in the fabric. However, if tugged on with an extreme amount of force the snaps could break and may require resewing. The calculator pockets showed to be sturdy with heavy amounts of force placed on them when placing in calculators.

Desktop Caddy[edit | edit source]

To test durability of the Desktop Caddy each team member of Team Falcon-Jacks dropped each of the Desktop Caddy's from shoulder height to make sure no chipping of the melamine (the white plastic coating) or breaking would occur. After doing so each caddy was inspected, to find only one with a slight chip on the corner, though it was easily fixable by sanding the area quickly. To test effectiveness they were filled with supplies and tools to make sure that the students could easily handle them, and manage their supplies in their caddy.

Street Sign Storage Caddy[edit | edit source]

The effectiveness of the Street Sign Storage Caddy was tested by filling it full of fully loaded Desktop Caddies, to make sure it could handle the weight from the Desktop Caddies. The Street Sign Storage Caddy was capable of holding up all the Desktop Caddies with no issues. To make sure it was completely safe a member of Team Falcon-Jacks ran their hand along every previously sharp area to make sure the vinyl tubing was doing its job and covering all the sharp places. The members of Team Falcon-Jacks also spent approximately five minutes using the caddy extensively. The members put the Desktop Caddies in and out, did things around the caddy to test its stability, and made sure there would be no hidden sharp parts or dangerous parts that were previously overlooked. In the five minutes of extended use no injuries occurred. The members of Team-Falcon Jacks also applied various amounts of force in order to make sure it wouldn't tip, which it didn't. It stayed stable on the flat surface it was located on.

How to build[edit | edit source]

Upcycled Hanging Caddy[edit | edit source]

Materials & Tools Required[edit | edit source]

Sewing machine, thick thread, dishtowel(s), fabric for pockets (preferably cotton), sew on snaps, hanger, and plastic for labeling pockets if desired.

Calc Caddy 1.jpg

Measure size of calculators to be used before cutting fabric. Cut fabric for pockets to desired size as well as plastic used for labeling system. Take in account if fabric needs to be hemmed as this will make the pockets smaller.

Calc Caddy 2.jpg

On dishtowel, measure how much material is needed to allow to be hung off a hanger.

Calc Caddy 3.jpg

Before sewing snaps, measure where the snaps can be placed on fabric and covered by the pocket. This is because the snaps are visible from the front, so we will be sewing pockets over what can be seen for aesthetic purposes.

Calc Caddy 4.jpg

Sew snaps in desired location, be sure they line up when snapped together and are not crooked.

Calc Caddy 5.jpg

Measure the pocket placement as well as plastic labels and pin to fabric.

Calc Caddy 6.jpg

Sew on top label first.

Calc Caddy 7.jpg

Sew a hem on the top and bottom of the fabric for the pockets.

Calc Caddy 8.jpg

If a hem was not considered on the sides of pocket fabric use a zig zag stitch (to keep fabric from fraying over time) when sewing onto dishtowel.

Calc Caddy 9.jpg

Sew pockets and plastic labels on together so that only one stitch is needed (for aesthetic purposes). If using a hem, fold small piece of fabric over on each side and continue to sew all together. DO NOT sew top of pocket to dishtowel, as this creates the pocket.

Desktop Caddy[edit | edit source]

Materials & Tools Required[edit | edit source]

Wood (plywood or particle board preferred), drill, drill bit for wood, screws (all purpose wood screws), acrylic paint, clear coat, wood glue.

Desk Caddy 1.jpg

Cut wood material into desired size. Make sure to include the width of the wood when measuring.

Desk Caddy 2.JPG

Before drilling pilot holes, make markings on the wood to ensure where needs to be drilled.

Desk Caddy 3.JPG

Carefully drill pilot holes using proper drill bit; there are different types of drill bits required for different materials. Make sure hole has gone through both wood pieces.

Desk Caddy 4.JPG

Slowly drill screws in pilot holes. Be sure to screw in straight otherwise wood may crack.

Desk Caddy 8.JPG

Before cutting wood for the inner dividers of caddy, use cardboard to see what thickness would be preferred. The thickness of the inner divider will change the size of the cells used for storage.

Desk Caddy 6-2.JPG

Cut inner divider wood to desired size.

Desk Caddy 7.jpeg

Glue inner divider wood pieces together before inserting and gluing into caddy body.

Desk Caddy 8-2.jpeg

Once dividers have dried, carefully glue into the caddy body. Be sure to clean up any excess glue inside caddy body.

Desk Caddy 9.JPG

Glue handle together prior to drilling in screws. This ensures that the handle will not rotate once attached to caddy body.

Desk Caddy drillin.JPG

Once glue has dried on handle, secure handle by drilling in screws.

Desk Caddy 11.jpg

Put glue on lower insides of handle (that will be against caddy body) as glue is still wet attach to sides of caddy body and drill in final screws.

Desk Caddy 12.jpg

Paint as desired. Cover outside of desktop caddy with a clear coat to protect paint.

Street Sign Caddy[edit | edit source]

Materials & Tools Required[edit | edit source]

Street signs (depending on size desired), l-brackets(20 - 1½"), drill, bolts, nuts, mallet, vinyl tubing, super glue.

Street caddy cut.jpg

Cut aluminum street signs to desired size. be sure to use the proper blade for cutting aluminum

Street Caddy 1.JPG

Make markings on street signs for where to drill the holes for the brackets that will connect signs together. Be sure to use the proper drill bit for drilling through aluminum.

Street Caddy 2.JPG

Be sure holes are right size for bolts, and the holes match up with the plotted angle.

Street Caddy 3.JPG

Insert bolts into bracket through correct street signs and tighten.

Street Caddy 4.JPG

Check to make sure sides of signs are flush against each other and brackets are straight.

Street Caddy 5.JPG

Attach plotted angle to all corners to maintain stability.

Street Caddy 6.JPG

Measure where to place shelves for cubbies. And Attach cubbies with L-brackets and bolts.


Make sure shelves are leveled with one another.

Street Caddy 8.jpg

Bend top of caddy using a machine, or can be done with a mallet with sign clamped to hard, sturdy surface. Attach top using 4 L-brackets on the sides and a plotted angle on the back.

Discussion[edit | edit source]

During the process of building all three caddy designs, The Falcon-Jacks experienced several issues with the original designs.

Hanging Calculator Caddy[edit | edit source]

Team Falcon-Jacks originally decided on using a quilted method to create the backing for the Hanging Calculator Caddy. Upon further research and testing, Team Falcon-Jacks decided to use new store bought dishtowel as a backing. This decision was based upon dishtowels being more sturdy then a quilted method, and more likely to hold up to the wear and tear of middle school students.

Desktop Caddy[edit | edit source]

The original design of the Desktop Caddies, used only screws to connect the handles to the body of the Desktop Caddy. This turned out to not work because the screws allowed for the handle to rotate, which made carrying them unstable. Instead, a combination of wood glue and screws were used to reassure there would be no movement while being carried. The melamine, which was already coated on the upcycled particle board, also turned out to be sharper than expected once cut. Because of this, the sides were sanded down as much as they could be. The particle board also split on the bottoms in some caddies because of the pilot hole was too small. Once a large pilot hole was provided the drilling went smoothly. All cracks were covered with wood putty.

Street Sign Storage Caddy[edit | edit source]

Almost the entire design Street Sign Storage Caddy had to be re-designed once it became clear that using wood would be too heavy, and it wouldn't hit the upcycling criteria. There were many other options for building a storage caddy, but focusing on the aesthetic criteria and the upcycled criteria, street signs became a clear option. After purchasing 36 pounds of street signs, Team Falcon-Jacks redesigned, and renamed the caddy design to the Street Sigh Storage Caddy. The caddy was now to be built entirely out of street signs. Large ones were used to make the backing, the sides, the top, and the bottom. Smaller parking signs were used to make each of the interior pockets, and the hinged whiteboard area. After showing the Street Sign Storage caddy to the client, Team Falcon-Jacks decided plotted angles instead of L brackets to hold together the larger parts of the Street Sign Storage caddy, so that it would last many years of hard use.

Next Steps[edit | edit source]

Due to the durability of the Street Sign Storage Caddy there are no anticipated repairs within the first 3 years of use. The Desktop Storage Caddy is anticipated to not require any repairs after the first 2 years of use. However, if dropped on a hard surface, such as cement, form a height greater that 5 feet there may be some chipping on the sides of the caddy. The Hanging Calculator Caddy was shown to be the least durable our of all three caddy designs, and would require minimal repairs annually depending on its use. The table below describes the material needed and cost of material required to fix any damages.

Table-3: Maintenance Costs
Item to Repair Frequency Projected Cost/Years ($)
Snap Pins 1 year $2.99 per pack
Wooden Hangers 1 year $24.99 per pack
Thread for Sewing Repairs 1 year $2.79 per spool
Total $30.77

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Discussion[View | Edit]

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