Christmas Zig-Zag Ski Lift & Skier

The Christmas Skier is a classic Christmas Toy where various Christmas themed characters ski down a track and are raised back to the top of the “slope” by a Zig-Zag Lift Mechanism. I present my custom simplified version in both Hand-powered and Motorized Versions. 

Print & Assembly Instructions:

Manual (Hand-Powered Version)

Non-Printed Parts Needed:

1x 608Z Bearing - Per Skier Model

Skier:

1. Print all Skier parts and check fitment.
2. Place bearing on axle and permanently glue axle to Mount with CA glue.
3. Glue Skier Model to Mount Assembly with CA glue.
4. Fin

Track:

Print all track parts and check fitment. (NOTE: MANUAL AND AUTOMATIC MODELS HAVE DIFFERENT TRACKS. THOUGH THE DIMENSIONS ARE THE SAME, THE TRACKS ARE MIRRORED FOR EACH DESIGN RESPECTIVELY) 

1. Affix Support Pole to Straight Slope Track section with CA Glue.
2. [Optional: Affix Ski Slope Signs to Support Pole & Zig-Zag Outer.] 
3. Insert Handle through Zig-Zag Outer Piece and affix into the Manual Cam with CA glue. Note: The Handle and Cam assembly should be able to freely rotate in the Zig-Zag Outer Piece.
4. Insert Upper and Lower Track Curves onto their respective ends of the Straight Slope Piece.[Optional: Glue with CA Glue, or leave unglued for future disassembly. ]
5. Place Track Assembly onto Zig-Zag Outer Piece by vertically lowering it onto the track notches at the top and bottom of the lift section.
6. Place Zig-Zag Inner piece within the Zig-Zag Outer piece by lowering it vertically into place, being sure to align the Cut-Out with the Cam. 
7. Fin

Place the Skier in the Bottom Track Section of the Zig-Zag and get cranking! or if you prefer a less strenuous option…

Automatic (Electric Motor Powered Version)

Non-Printed Parts Needed:

• 4x M3x 8mm Bolts
• 2x 608Z Bearing - Per Skier Model
• 1x N20 Gear Motor DC 3V-6V
  • Amazon Link here: (https://a.co/d/1lqfZiV)
• 1x KAN-28 Electric Switch
  • Amazon Link here: (https://a.co/d/9ScSZYW)
• 1x AAA Battery
• Electric Wiring - At Least 6"

Skier:

1. Print all Skier parts and check fitment.
2. Place bearing on axle and permanently glue axle to Mount with CA glue.
3. Glue Skier Model to Mount Assembly with CA glue.
4. Fin

Track:

Print all track parts and check fitment. (NOTE: MANUAL AND AUTOMATIC MODELS HAVE DIFFERENT TRACKS. THOUGH THE DIMENSIONS ARE THE SAME, THE TRACKS ARE MIRRORED FOR EACH DESIGN RESPECTIVELY) 

Initial Assembly:

1. Affix Support Pole to Straight Slope Track section with CA Glue.
2. [Optional: Affix Ski Slope Signs to Support Pole & Zig-Zag Outer.] 
3. Place 608Z Bearing onto one half of the Automatic Cam, then affix the other half of the Automatic Cam to the first half with CA glue. (NOTE: Be extra careful with CA glue at this stage, making that that the bearing can still continue to rotate freely.)
4. Place Cam Assembly within the Zig-Zag Outer so that it will align with the electric motor during its installation. 

Wiring:

1. Place the KAN-28 Switch in its designated Slot
2. Secure using 2x M3 x 8MM Bolts (Note: Leave Slack to allow easy wiring connection in future steps)
3. Insert and Fully Secure 2x M3x 8MM Bolts into Battery Slot from sides. (Note: Leave Slack to allow easy wiring connection in next steps) (CAUTION: MUST BE DONE PRIOR TO ELECTRIC MOTOR INSTALLATION AS BOLT REQUIRES ACCESS THROUGH MOTOR SLOT TO ACCESS.)
4. Wire from Battery Terminal to Switch and Secure wire using Bolts left slackened in earlier step. 
5. Wire From Electric Motor to Switch & Battery Terminal respectively and Secure wire using Bolts left slackened in earlier step. 
6. Test Wiring Connections and Motor to ensure solid circut connection before moving onto Final Assembly

Final Assembly:

1. While keeping the Cam Assembly aligned, insert the Electric Motor Shaft into the Cam Assembly and lower the Motor itself into its slot in the Zig-Zag Outer. 
2. Secure Motor in place by CA gluing the Electric Motor Cover into the slot above the motor. The Electric Motor Axle and Cam Assembly should be able to freely rotate in the Zig-Zag Outer Piece. (CAUTION: BATTERY TERMINAL CONTACT INSTALLATION MUST BE COMPLETE PRIOR TO ELECTRIC MOTOR INSTALLATION AS BOLT REQUIRES ACCESS THROUGH MOTOR SLOT TO INSTALL.)
3. Re-Check all wiring connections and test Electric Motor operation with Cam Assembly installed. 
4. Insert Upper and Lower Track Curves onto their respective ends of the Straight Slope Piece. [Optional: Glue with CA Glue, or leave unglued for future disassembly. ]
5. Place Track Assembly onto Zig-Zag Outer Piece by vertically lowering it onto the track notches at the top and bottom of the lift section.
6. Place Zig-Zag Inner piece within the Zig-Zag Outer piece by lowering it vertically into place, being sure to align the Cut-Out with the Cam. 
7. Fin

Place the Skier in the Bottom Track Section of the Zig-Zag, insert a AAA Battery, and push the button for a thrilling Black Diamond Ski Run.