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How to Build a Toy Chuck Wagon

Building a mini chuck wagon is a fun project requiring some simple tools and a little work. Buy the hardwood plywood already cut from your local building supply store and the other materials are easily found as well. The wagon wheels can be ordered off the Internet if not available locally.

Things You'll Need

1, 24-by-36-inch sheet of plywood
Power drill with 3/8 inch bit and screwdriver bit
1-inch long x 1/4-inch wood screws
4, 2-by-4-inch boards 30 inches long
1/4-by-1/2 inch wood screws
10, 1 inch pipe straps
3, 12-by-36-inch sheets of plywood
3, 24-inch plastic hoops
30-by-36-inch piece of canvas cloth
Staple gun
2 strips of flat molding 36 inches long
3, 30-inch long hardwood dowels ½-inch diameter
4 large rubber washers
Four 1/4-inch fluted dowel pins
Metal strap hinge
1 gatehouse wooden knob

Instructions

Building the body
- 1
  Lay the 24-by-36-inch plywood piece flat on the work table.Place a 2-by-4 board on long side the of the plywood. Place it about 3 inches back from the front edge. Use the drill and long wood screws to attach one 2-by-4 piece on each side of the plywood.
- 2
  Measure back six inches from each end of the 2-by-4 board and use the drill and short wood screws to attach the pipe straps to the 2-by-4. Do this front and rear making sure the opening in the pipe strap faces towards the side. These will hold your wagon axles.
- 3
  Turn the work over and place two more 2-by-4 boards on the long sides of the top of the board 6 inches in from each side and attach with the drill and long wood screws.
- 4
  Place a plastic hoop in the front, middle and rear of the wagon standing them up. Place one of the 12-by-36-inch pieces of plywood down to cover the bottom of the hoops and 2-by-4 boards. Secure the plywood to the 2-by-4 pieces with the drill and long wood screws.This will make an attractive floor for your wagon.
- 5
  Place one of the 12-by-36-inch plywood pieces against the side of one of the bottom 2-by-4 boards and attach it with the drill and four long wood screws. Repeat on the other side.
- 6
  Use the drill and short wood screws to fasten a metal pipe strap over each of the hoops and into the sides of the wagon. This will hold the hoops firmly in place.
- 7
  Drape the canvas loosely over the hoops. Start on one side and staple the canvas to the wooden side board. Now place one of the flat molding pieces over the staples and attach it to the side board using the drill and three short wood screws. Pull the canvas taut and repeat this process on the other side
Attach the wheels and handle
- 8
  Slide the long hardwood dowels through the metal pipe straps you attached to the bottom. These are your axles.
- 9
  Slide a rubber washer over the end of each axle. Slide wheels onto the rear axles and place a rubber washer on next to the wheels.
- 10
  Use the drill with a 3/8-inch bit to drill a hole through the axle just past the wheel. Now pour some carpenters glue in the hole and push a fluted dowel pin into the hole. Tap the pin all the way into the hole and wipe off any excess glue. Repeat this process with the other three wheels.
- 11
  Use the drill and short wood screws to fasten the strap hinge to one end of the remaining 30-inch hardwood dowel. Attach the other end of the hinge to the front of the wagon. Try to get it in the center of the front edge of the wagon body.
- 12
  Use the drill and a long wood screw to attach the gatehouse wooden knob on the end of the handle you just made.

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