DIY Toy Forklift

The Parts

• 1

  Put on your safety goggles. Use the handsaw to cut three pieces from the 3/4-inch thick lumber: one to a length of 3 1/2 inches and the others to 1 inch. The 3 1/2-inch piece is the chassis and the 1-inch pieces are the seat and counterweight.

• 2

  Cut a 1 1/4-inch piece and a 2 1/4-inch piece from the 1/2-inch thick wood scrap with the handsaw. The 1 1/4-inch piece is the seat's back and the other piece is the hoist arm.

• 3

  Use the handsaw to cut the plywood scrap into pieces that include a 2-inch square, two strips that are 3/8 inch by 2 3/4 inches and two strips that are 3/8 inch by 2 inches; these pieces are the forklift's mast and forks.

• 4

  Cut four 1/4-inch thick disks from the 1-inch dowel for the forklift's wheels.

• 5

  Cut two 2 5/8-inch rods from the 1/4-inch dowel for the forklift's axles.

• 6

  Cut two strips of plywood: 1/2 inch wide and 1 inch long. These are the hoist arm's sliders.

Hoist Arm and Forks

• 7

  Make four 1/4-inch deep cuts into the hoist arm's bottom end at 3/8 inch, 3/4 inch, 1 1/4 inches and 1 5/8 inches. Punch out the 3/8-inch sections between the first and second cuts and between the third and fourth cuts.

• 8

  Spread wood glue into the hoist arm's notches. Slide the forks into the notches so that they're flush with the hoist arm's back.

• 9

  Spread wood glue on the bottom 1/2-inch sections of the hoist arm's sides. Center the sliders on the glued sections. Hold the sliders and forks in place with masking tape until the glue is completely dry.

Forklift Assembly

• 10

  Make 1/4-inch deep cuts into the chassis's front end, 3/8 inch from each side with the hand saw. From each side, make 3/8-inch deep cuts toward the cuts in the front so that you cut out two L-shaped sections.

• 11

  Make an 1/8-inch deep cut parallel to the front edge, 1/2 inch from the front. Make a parallel 1/8-inch deep cut 1/4 inch behind the first cut. Carve out the section between these two cuts with your 1/4-inch chisel, creating a groove.

• 12

  Glue the mast's 3/8-inch wide strips into the front end's carved out corner sections. Glue the 2-inch square into the groove. Make sure that these pieces are at perfectly straight angles to the chassis.

• 13

  Glue the seat to the chassis 1/2 inch behind the mast and the seat back behind the seat. Glue the counterweight 1/4 inch from the end of the chassis. Let the glue dry completely.

• 14

  Lay the forklift on its side. Make pencil marks 1/2 inch from the chassis's front and back at a height of 3/8 inch. Drill all the way through these marks.

Sanding and Lacquer

• 15

  Sand all surfaces of the forklift, hoist arm, and wheels thoroughly. Use medium-grit sandpaper first, then fine-grit sandpaper.

• 16

  Apply a coat of lacquer finish to the forklift, hoist arm and wheels. Let the lacquer dry completely.

• 17

  Drill straight through the center points of all wheels. Apply glue to the holes of two wheels. Insert the axles.

• 18

  Slide the chassis holes onto the axles when the glue is dry. Apply glue to the holes of the other two wheels. Slide the wheels onto the axles.

• 19

  Place the forklift on its wheels. Slide the hoist arm, forks first, into the mast.