Build two flat Warren trusses from craft sticks, then join them with cross-bracing to form a bridge. The key to a sturdy model is accurate triangles, well-glued joints, and keeping both side trusses vertical and square while the braces set. Make’s 2015 project lists a capacity of more than 100 pounds, but that is the project’s claim—not a guaranteed or standardized rating for every build.
How a Warren truss works
A Warren truss is made from a row of side-by-side triangles, with each triangle inverted relative to the next. The long upper and lower members are the chords; the slanted members connecting them are the webs. For this project, you will make two matching flat trusses and connect them with cross pieces to create a three-dimensional bridge.
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Make: contributing editor William Gurstelle describes the Warren pattern as “tried and true,” and characterizes it as easy to build, strong, and relatively lightweight. The project also names Howe and Pratt trusses, but provides no comparative measurements; the useful distinction here is the Warren truss’s alternating triangular web pattern.
The Tool Desk
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- 100 six-inch craft sticks or tongue depressors
- Balsa wood sheet
- Two standard bricks
- Hot glue gun and glue
- Utility knife and ruler
- Optional for testing: plate weights, concrete blocks, buckets of water, or another flat, heavy load
Work on a stable surface, follow the glue gun and utility knife manufacturers’ safety instructions, and let hot glue set before handling or loading joints.
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Build the two side trusses
- Cut the gussets. Use the ruler and utility knife to cut 14 squares from the balsa sheet, each 2 inches on a side. These small plates reinforce the joints where the craft sticks meet.
- Lay out the first truss. Place seven gussets on a flat work surface as a template for one side truss. Arrange craft sticks into aligned, alternating triangles. Make: specifies equilateral triangles for the pattern.
- Glue the joints. Hot-glue the sticks where they meet on the gussets. Keep the members aligned and allow the glue to set before lifting the truss.
- Double the truss. Turn the flat truss over and glue additional craft sticks to the reverse side, as the project directs for “double strength.”
- Make the second side. Repeat the layout and gluing process so the bridge has two matching trusses.
Optional chord reinforcement
Make’s instructions identify the top and bottom chords near the bridge center as the locations of greatest force in this model. They suggest adding a craft stick at those points as optional reinforcement. This is a project-specific suggestion, not a guarantee of a particular increase in capacity.
Join the trusses into a bridge
- Set up the sides. Place two bricks 4 inches apart. Stand the trusses vertically against the bricks, parallel to one another, and use tape to hold three web members of each truss to the bricks while you assemble the frame.
- Add the cross pieces. Glue struts and braces between the side trusses across both the top and bottom. Keep each truss vertical and each cross piece perpendicular to the sides.
- Brace the ends. Add braces across each end of the bridge. Check that the two trusses remain parallel and square to the cross pieces as the glue sets.
Make’s instructions warn that even a small lean can cause premature failure. Recheck the alignment while the bridge is being assembled and before it is loaded; a crooked frame can put the joints and members under uneven stress.
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Load-test the finished model safely
- Move the bricks onto the floor and set them 14 inches apart.
- Rest the bridge ends on the bricks, centered so the gap between supports is clear.
- Add a flat, heavy load gradually and distribute it evenly. The project suggests concrete blocks, barbell weights, buckets of water, or another suitable load.
- Keep hands and feet out from beneath the bridge while adding weight. Stop if the structure shifts, a joint opens, or a member begins to bend or crack.
You can load the bridge until it fails, or skip destructive testing and paint and display it. Make’s 2015 project states that its model can hold more than 100 pounds; it does not provide standardized test conditions, measured repeat trials, or a guarantee for other builds. Materials, alignment, glue joints, and construction quality can all affect how an individual model performs.
Quick Recap
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