Introduction: Custom Kids Wagon.

Picture of Custom Kids Wagon.

Made this wagon from scratch as a baby gift for friends. I had built 1 in the past from a radio flyer, but this time went totally custom and home built (apart from the wheels)

Step 1: Make the Box.

Picture of Make the Box.

I really wanted to go with an ammo crate style seating area. it was made from pine to keep the weight down as much as possible.

Step 2: Seal the Wood.

Picture of Seal the Wood.

Since i was using pine and it soaks up water like i sponge, 3 coats of sealer was added.

Step 3: Paint the Box.

Picture of Paint the Box.

Simple spraypaint was used to create the theme. Some truckbed liner was added to give some protection for the wood.

Step 4: Cut Steel for the Frame

Picture of Cut Steel for the Frame

Cutting all pieces according to a plan makes this step much easier. Drawing things out and measuing means no surprise later.

Safety counts here, use the appropriate protective gear.

Step 5: Weld Together Frame Pieces.

Picture of Weld Together Frame Pieces.

Weld together the frame sections on a flat surface to ensure things end up straight.

Step 6: Setup Steering Design.

Picture of Setup Steering Design.

Assemble the parts for steering the wagon. Tie rods with heim joints were used to add car-style control.

Step 7: Sandblast Parts

Picture of Sandblast Parts

Since i have access to a sandblaster it was used to get all the parts down to fresh metal. This can be done just as well with a wire brush on a drill or by hand with sandpaper if needed.

Step 8: Prime

Picture of Prime

Prime all parts before painting to ensure years of fun

Step 9: Paint, Paint, Paint!

Picture of Paint, Paint, Paint!

4 layers of paint were used to add extra durability.

Make sure to let things dry and cure before flipping to paint another section.

Step 10: Add Comfort.

Picture of Add Comfort.

Some paracord was used to wrap the handle to add some comfort.

Step 11: Assemble.

Picture of Assemble.

Now is the time to put everything together. Some metal plates were used to rest the wheels on when stopped so that the wagon doesnt roll away by itself.

A family member knit a matching blanket as well.

Step 12: Admire the Finished Product

Picture of Admire the Finished Product

Since this was my 2nd go at a wagon I really enjoyed how it turned out and learned many things that could be applied if a 3rd ever gets made.

I hope this instructable gives some inspiration and if you have any questions leave a comment and an answer will be provided

Dont be scared to vote for this in the metalworking contest



HomeBrewski (author)2016-04-13

Great build, I'm going to save it for later in case I ever get time to make something like this... Can I ask why the rear wheels are cantilevered? Is it just for style, or did you have another purpose? Again, great job!

thezapman (author)HomeBrewski2016-04-13

thanks for the feedback. the wheels are just cambered for a bit if style. but they also add a bit of extra stability to the wagon as a side effect.

bikestew (author)2015-08-16

where did you source your steering components?

thezapman (author)bikestew2015-08-16

The only steering pieces which werent home made were the bolts and heim joints. bolts i buy locally at a fastner store, the heim joints i bought on

BradleyH5 (author)2015-08-16

Sweet deal

Big Projects (author)2015-08-14

Nice Idea I love it!

Kiteman (author)2015-08-14

Oh, that's a crackin' job!

gumby_kevbo (author)2015-08-14

Unlike most wagons, That looks quite stable. If there are any hills around, though, it aught to have some sort of brakes. No self respecting kid will
Fail to use it as a gravity powered go-kart. No
Self respecting kid will have a plan for what to do when it gets rolling too fast or how to stop at the bottom.

Just plates hinged to rub on the rear tires would work.

thezapman (author)gumby_kevbo2015-08-14

brakes are a good idea and something i might add if i biuld another. the design is basic like most other wagons "radio flyer" for example has no brakes.

gumby_kevbo (author)2015-08-14

Also, I can't tell if you put any Ackerman differential in the steering. If the steering knuckles are made so that an imaginary line from the king-pin (bolt) through the tie-rod attachment passes through the center of the rear axel, this approximates the right action. The angle between the front spindle and the steering horn should not be 90deg. In other words.

The idea here is that the inner wheel follows a tighter radius than the outer wheel, and skewing the steering horns toward center causes this to happen.

avocadostains (author)2015-08-13

Top notch. Nary has been seen by I finer a wagon.

thezapman (author)avocadostains2015-08-13

Thanks! it was a fun project and these things are addictive. 2 made so far and the 3rd is being planned.

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