How to Make a Wooden Toy Bus

Cutting and Gathering the Pieces

• 1

  Using the skill saw, cut a 3/8-inch thick piece of plywood 12 inches long by 4 inches wide. Cut 1/2-inch deep and 1-inch wide arches in each corner for the wheel wells and position them so that the wheels will be 6 inches apart and the back wheels will be 3 inches from the back of the bus.

• 2

  Cut two pieces of 1/4-inch plywood 2 1/2 inches wide and 12 inches long for the sides of the bus. Cut two 1/2-inch deep and 1-inch wide arches in each piece for the wheel wells. For windows, use a jig saw to cut out 1/2-inch by 1/2-inch squares along each piece.

• 3

  Use a four-inch by four-inch block of wood for the front of the bus and, using a jig saw, cut holes for a window on both sides. Trim out a square for the door on one side 1/2-inch deep that can be painted to look like a real door.

  Use a 1-inch by 4-inch block for the back of the bus.

• 4

  For the top of the bus, cut a 17-inch long by 4-inch wide piece of 5/8-inch plywood.

Gluing the Pieces Together

• 5

  Using wood glue, glue the sides to the bottom and let dry. With wood screws, fasten each wheel in each wheel well to the 3/8-inch bottom.

• 6

  Glue the front and back of the bus to the ends of the sides. At this point, the bus should be 17 inches long.

• 7

  Glue the top of the bus to the sides, the back, and the front of the bus. The front and back of the bus should fit under the top.

Finishing

• 8

  Use a sander to shape a curve in the back and the front of the bus. Sand all edges smooth.

• 9

  For extra strength, use wood screws to attach the sides, top, and bottom to the front and back of the bus. Use a wood punch to countersink each screw and fill the holes with wood putty. Use the type of putty that will hold paint.

• 10

  Use the ends of 2 round-tipped dowels for headlamps and glue to the front of the bus.

• 11

  Paint the bus a bright color or paint it in colors to match a school or metro bus.