Take the portfolio route rather than a single project for AS. Start by marking their GCSE projects against AS criteria (you can reuse them!) Use these as a safety net, look at the gaps and plan accordingly. Short projects on jewellery based on geometry/nature, "in the style of"...could be clock, mirror, photo frame etc. non-functioning product modelling - hairdyer, iron etc., lighting based on architecture, bathroom accessories in clear acrylic (using suckers from Hindleys). Go for quality rather complexity. Focus each project on different aspects - research, planning etc. Don't try to do complete mini GCSE projects it will bore them to death. Short deadlines. High level presentations to rest of group. Use Powerpoint and present as electronic portfolios or mount work as "interview portfolios" (can be A2).