How to Make Turning Wheels on Toys

Setup

• 1

  Select your material for the wheels. Choose hardwood lumber that is straight, and free from splits and cracks and open knots. Lumber with an even color and straight grain is best, as this indicates consistency in the density of the material.

• 2

  Install the proper size of hole saw into your drill. Fit the centering bit into the chuck as you do a standard drill bit, and tighten the chuck snug.

• 3

  Clamp the lumber in place on your work table with a C clamp, so the portion you intend to cut your wheel from hangs off the edge of the table.

Cutting

• 4

  Set the tip of the centering bit on the face of the material and start the drill, applying steady pressure to keep the bit from "walking." Maintain steady pressure, running the drill at full speed on high. Keep the hole saw balanced, so the teeth of the saw cut in evenly.

• 5

  Keep the saw running until it cuts through the other side. Use a nail or thin screwdriver to push the wooden disc from the hole saw by poking through the back of the saw to drive it out. Avoid touching the saw, since it will be hot.

• 6

  Sand the wheel smooth with fine grit sandpaper, 150 grit works well.

Installation

• 7

  Cut a piece of 1/4-inch wooden dowel the thickness of the toy, plus the thickness of two wheels and 1/8-inch, if you intend to mount them as a pair on an axle.

• 8

  Glue the ends, fitting one wheel onto the axle. Run the axle through the body of the toy and fit the other wheel on the other side.

• 9

  Mount the wheel without an axle using a 1/4-inch lag bolt, with a threadless neck, so the first inch of bolt under the head has no thread, and the wheel turns smoothly on it.

• 10

  Drill a 3/16-inch hole in the toy and tighten the bolt into the hole until it is almost flush against the wheel, leaving it turning freely.