How to Build a Toy Wagon

Building the Box

• 1

  Cut wagon pieces from 3/4-inch plywood with a circular or table saw. Cut two sides at 6x24 inches, cut a front and back at 6x14 1/2 inches, cut a bottom at 16x24 inches. Cut wagon wheels from the plywood using a 6-inch hole saw on a drill, make four. Cut two pieces of 2x4 at 17 inches long.

• 2

  Build a 24x16-inch rectangle using the two 6x24 and the two 6x14 1/2-inch pieces. Attach the corners with glue and nails.

• 3

  Run a bead of wood glue along the edge of the rectangle and set the plywood bottom on top with all four edges flush. Nail the bottom to the rectangle.

• 4

  Sand the wagon box thoroughly to remove any splinters or rough spots. Sand the wheels also, rounding over the edges slightly.

Adding the Wheels

• 5

  Attach the two 2x4s to the bottom of the wagon box flush along each 16-inch end. Use four 1 1/4-inch screws in each 2x4 through the inside of the wagon box through the bottom to attach them.

• 6

  Drill a hole in the center of each of the four 2x4 ends with a 3/8-inch drill bit to a depth of 2 inches. Tap a 1/4-inch T nut into each hole with a hammer. T nuts are available in your local hardware store.

• 7

  Drill out the center hole of each wheel to 1/4 inch. The hole from the hole saw may be this size already, run the bit through to clean up the hole for smooth wheel action.

• 8

  Attach each wheel with a 1/4-inch by 3-inch machine bolt. Add a bit of thread lock compound to the end thread of your bolt before installing. Use 1/4-inch fender washer between the wheel and the box and a second between the wheel and the bolt head. Tighten the bolt so the wheel does not slide on the axle, but still turns freely.

Adding the Handle

• 9

  Measure and use a quick square to mark the exact center of the front of the box. Use a 1/2-inch paddle bit to drill a hole through the front of the wagon box, centered on that mark. Sand the edges of the hole.

• 10

  Cut a piece of 1/2-inch, soft nylon rope 28 inches long. Burn the ends of the rope slightly to keep it from unraveling. Tie a knot to prevent it from passing through the hole in the wagon box at one end of the rope. This will be your handle.

• 11

  Slip the untied end of the rope through the hole in the wagon box so the knot is snug against the inside of the wagon box. Tie a second knot close against the face of the box to prevent the rope from slipping back through.