Making the Train Cars
Train cars are square in nature, so making them is easy. Try making them out of scrap wood. Cut pieces of wood to the shape and size desired. Sand down the edges and paint them with solid colors. If you desire, add artistic details to make them look even more like train cars.
Making the Engine and Caboose
To make the engine, start with a flat strip of wood as a base. Make sure the base is thick enough to drill through from the side, because you will need to make holes for the axles later.
Cut and glue a section of large, round dowel to the front of the base, and make a cab at the back of the base out of a small, square block of wood. Add a triangular piece of wood to the top of the cab to form a roof. Cut smokestacks out of smaller dowels. Drill holes in the top of the large dowel and attach the smokestacks with wood glue. Paint as desired.
For the caboose, cut a long, skinny triangle and place it on top of a rectangular block, forming a roof. Paint the caboose red. Leave both pieces in solid colors, or use a fine paintbrush to add more details. Look at photos of real engines and cabooses for inspiration.
Adding Axles to the Cars
Make an axle by cutting two small circles from wood. Drill a hole in the center of each circle and insert a dowel of the same diameter as the hole. Drill a slightly larger hole through the train car where the axle will be attached. Glue one end of the dowel into a wheel, feed it through the hole in the train car, and glue the other wheel to the other end of the dowel. Put two axles on each car, including the engine and caboose.
Connecting the Cars
There are many ways to attach the cars. To make the cars detachable from each other, explore the hardware store. Alternatively, connect cars permanently using screw-in eyebolts and short lengths of vinyl-coated chain.
For added motor skill development, let children connect the cars in different ways. Attach two cars by tying them together with ribbon, with velcro connectors, with carabiners or with any other type of connector you find. Exploring the hardware store will provide many different options and ideas for creative ways to connect cars.