Small children love to pull toys around. A wagon with cargo can make their day.

Supplies

These are the tools and materials I used. This project can be done using hand tools but it will, of course, be more difficult.

TOOLS AND MATERIALS

Table saw

Disc sander

Electric drill

Drill press

1/8" bit with countersink

Phillips screw driver

1-1/4" x #8 Phillips screws

2-3/4" hole saw for wood

1/16" bit

Hammer

1-1/4" x 16 wire finish nails

Wood glue

3/8" drill bit

WAGON COMPONENTS

1- 1/2" x 12" x 8" plywood or other sheet wood (bottom of the wagon)

2- 3/4" x 12" x 2-1/4" pine or other wood (sides)

2- 3/4" x 6-1/2" x 2-1/4" pine or other wood (front and back)

2-1-1/2" x 5-3/4" x 1-1/2" pine or other wood (tops of axle holders)

2-1/2" x 5-3/4" x 1-1/2" pine or other wood (bottoms of axle holders)

2- 1/2" x 8" dowel (axles)

4- 3/4" x 2-3/4" wheels

1- 3/16" or 1/4" x 4' nylon rope (fuse the ends)

1- 1/2" x 3-1/2" PVC pipe (handle)

OPTIONAL

3-1/4" x 3" x 2-1/4" wooden blocks (crates)

12- 9-1/2" x 1" straight shrub prunings (logs)

Sharpie marker

Ruler

Step 1: The Wagon Box

Cut all of the components to size and sand all of the edges to remove slivers and rough edges. Sand the ends of the axles so they will fit inside the holes in the center of the wheels. If possible use a drill press to cut out the wheels from 3/4" stock and smooth off the outer edges of the wheels. The axle holders, both top and bottom, will need a dado (groove) cut down the center in the long dimension to hold the axle. Make the grooves about 5/16" wide and 3/16" deep. As you make the cuts, check the fit by holding the tops and bottoms together and making sure the axle turns freely in the aligned slots.

Always drill pilot holes with countersink for the screws to make assembly easier and to help prevent splitting the wood.

Drill three pilot holes, from the underside, along each of the long sides of the bottom of the wagon, 1" from each end and in the middle, 3/8" from the sides of the plywood. Assemble the sides to the bottom using the Phillips screws. Fit the front of the wagon between the sides. Drill one pilot hole through the side into the front piece and install a screw to hold it in place and then repeat for the other three screws. Apply wood glue before assembly if you want. Repeat the process for the back pice of the box.

Step 2: The Wheels

With the box of the wagon up, mark the four locations for screw holes. The holes should be 2" from the front and back and 2" from the left and right sides. Drill and countersink.

Turn the box over (upside down) and draw lines 1-1/4" from the front and the back of the wagon, from side to side. These lines are used to align the edges of the top axle holders. Apply glue to the top of the top axle holder. Securely hold it in position while you carefully turn the wagon box over and drill pilot holes into the axle holder through the holes in the bottom of the box. Install screws. Repeat for the second top axle holder.

Apply glue to one end of an axle and insert it into the center of one of the wheels. Repeat for the second axle and a wheel.

Align one of the axle bottoms with one of the top axle holders. Hold it while you drill a 1/16" pilot hole about 1" deep about 3/8" from the long side and 1/2" from the end of the piece. Apply glue to the mating surface of the part. Realign the part and secure it with a wire nail. Drill the other three pilot holes in similar locations at the other corners of the part and install three more wire nails.

Repeat the process for the other axle holder.

When the wheel/axle glue has dried, insert one of the axles through the axle holder and glue the second wheel to it. Use the hammer to gently drive the wheel onto the axle. Repeat for the second wheel/axle.

Step 3: Finishing

Mark the middle of the front section of the wagon box and drill a 3/8" hole. Insert one end of the nylon rope through it and tie a knot large enough so it won't pull pack through the hole.

At the other end of the rope, insert it through the section of PVC and securly tie it using a square knot or two half hitches.

You may want to add some lettering to the sides of the wagon using a Sharpie marker. 3/4" is a good height if you put two lines of text with 1/4" between rows.

For something for kids to haul, consider 9-1/2" x 1" shrub pruning sections to serve as logs. 3-1/4" x 3" x 2-1/4" wooden blocks made to look like wooden crates work well. Use a Sharpie to draw lines so the blocks look like they are made from wooden boards.

Sign and date your project. You can present the wagon to a young child or just keep it at home for little ones to play with when they visit.