How to Build a Toy Wagon

Creating a simple toy wagon out of easy-to-obtain parts is a task that anyone who can cut a board and drill a hole can do. All of the parts are easily obtainable from your local hardware store and you may already have the tools you'll need sitting in your garage.

Things You'll Need

• 3/4-inch plywood
• 2 x 4 lumber
• 6-inch hole saw
• Circular or table saw
• Wood glue
• Nails
• Power sander
• Drill and bits
• 1/4-inch machine bolts
• 1/4-inch fender washers
• Quick square
• 1/2-inch rope

Instructions

Building the Box

1. Cut wagon pieces from 3/4-inch plywood with a circular or table saw. Cut two sides at 6x24 inches, cut a front and back at 6x14 1/2 inches, cut a bottom at 16x24 inches. Cut wagon wheels from the plywood using a 6-inch hole saw on a drill, make four. Cut two pieces of 2x4 at 17 inches long.

2. Build a 24x16-inch rectangle using the two 6x24 and the two 6x14 1/2-inch pieces. Attach the corners with glue and nails.

3. Run a bead of wood glue along the edge of the rectangle and set the plywood bottom on top with all four edges flush. Nail the bottom to the rectangle.

4. Sand the wagon box thoroughly to remove any splinters or rough spots. Sand the wheels also, rounding over the edges slightly.

Adding the Wheels

1. Attach the two 2x4s to the bottom of the wagon box flush along each 16-inch end. Use four 1 1/4-inch screws in each 2x4 through the inside of the wagon box through the bottom to attach them.

2. Drill a hole in the center of each of the four 2x4 ends with a 3/8-inch drill bit to a depth of 2 inches. Tap a 1/4-inch T nut into each hole with a hammer. T nuts are available in your local hardware store.

3. Drill out the center hole of each wheel to 1/4 inch. The hole from the hole saw may be this size already, run the bit through to clean up the hole for smooth wheel action.

4. Attach each wheel with a 1/4-inch by 3-inch machine bolt. Add a bit of thread lock compound to the end thread of your bolt before installing. Use 1/4-inch fender washer between the wheel and the box and a second between the wheel and the bolt head. Tighten the bolt so the wheel does not slide on the axle, but still turns freely.

Adding the Handle

1. Measure and use a quick square to mark the exact center of the front of the box. Use a 1/2-inch paddle bit to drill a hole through the front of the wagon box, centered on that mark. Sand the edges of the hole.

2. Cut a piece of 1/2-inch, soft nylon rope 28 inches long. Burn the ends of the rope slightly to keep it from unraveling. Tie a knot to prevent it from passing through the hole in the wagon box at one end of the rope. This will be your handle.

3. Slip the untied end of the rope through the hole in the wagon box so the knot is snug against the inside of the wagon box. Tie a second knot close against the face of the box to prevent the rope from slipping back through.

References

• Buildeazy:Child's Walker