How to Make a 6-inch Wooden Covered Wagon

Construct the Wagon Box

• 1

  Cut one piece of 1/8-inch thick balsa wood or rigid craft foam to a 2-by-6 inch dimension, using a sharp artist's utility knife, to form the wagon-bed bottom.

• 2

  Cut two pieces of 1/8-inch thick balsa or rigid craft foam to a 1-by-6 inch size to form the sides of your wagon bed. Cut two 1-by-2 inch pieces for the front and back of the wagon bed.

• 3

  Assemble the wagon bed by butting the front, back and sides against each other to create an open-topped box frame. Apply instant adhesive along one corner joint at a time.

• 4

  Apply instant adhesive along the top edge of the frame and position the wagon bottom. Allow the entire frame to dry for 1 hour or more before proceeding.

• 5

  Apply clear silicone adhesive to each inside joint of the wagon box, smoothing it into the cracks with a finger. Allow the adhesive to cure overnight. Repeat for all the outside joints of the wagon box.

• 6

  Turn the wagon box bottom-down. Cut drinking straws or straw-style coffee stirrers into 10 pieces, each 2 inches long. Attach one in each corner of the wagon box, standing on end.

• 7

  Turn the wagon box so that the front is facing you. Attach the remaining six straw pieces vertically every 1 1/2 inches along the sides of the wagon box, beginning in the front right corner, working to the back right corner. Repeat, beginning at the front left corner, working to the back left corner.

Assemble the Axles

• 8

  Draw a diagonal line from corner to corner on the 3/4 ends of each 3/4-by-2 inch wood block. Draw a second diagonal line, crossing the first. Use the cross point as your center mark.

• 9

  Secure one block in the work rest of your drill press, standing on its 3/4-inch end, with a 1/8-inch diameter bit centered on the cross point on the end of the block. Drill a hole through each block from end to end.

• 10

  Rub graphite powder on the 1/8-inch diameter, 5-inch long steel rod. Graphite allows the axles to turn more easily.

• 11

  Insert the axles through each wood block and pull them back and forth a few times to ensure that the graphite powder rubs through the entire length of the block.

• 12

  Scribe four 2 1/2-inch diameter circles on 3/16-inch balsa wood or rigid craft foam, pressing hard at the center point. Although not to scale, rounding the diameters for each of the Conestoga's wheels to 48 inches gives you a close-enough match that they will not create a jarring appearance.

• 13

  Mark the center point of each wheel with a black permanent marker. Sketch a Conestoga wagon wheel pattern onto each wooden circle. (See Resources 1, 2 and 3 for patterns.)

• 14

  Drill a hole through the center point of each wagon wheel.

• 15

  Place fender washers on each axle, followed by the wheel, another fender washer and an acorn nut. Use instant adhesive to attach the wheel assemblies to the underside of the wagon box, flush with each end. Allow to dry overnight.

Stretch Your Canvas

• 16

  Cut 5 pieces of 14- or 16-gauge black steel wire 10 inches long, depending upon which gauge will fit into the straw sections in the corners and along the sides of your wagon box.

• 17

  Insert each end of three of the wire sections into the straws along the sides to create the hoops that will support your wagon's canvas.

• 18

  Stitch a 1/4-inch casing at each 8-inch end of your canvas. Slide a 10-inch length of 14- or 16-gauge steel wire through each casing.

• 19

  Insert the ends of the wire into the straws at one end of the wagon box.

• 20

  Pull the cover across the other wires and insert the second pair of wire ends into their straw sections.

• 21

  Adjust the angle of the front and rear wire supports until your canvas stretches as tight as it will go.