Small children love to pull toys around. A hay wagon with bales can make them feel like they are hauling hay just like real farmers.

Supplies

TOOLS AND MATERIALS

Table saw

Disc sander

Electric drill

Drill press (optional)

1/8" bit with countersink

Phillips screw driver

1-1/2" x #8 Phillips screws

1-1/4" x #8 Phillips screws

2-3/4" hole saw for wood

Hammer

Wood glue

3/8" drill bit

Clamps

Large Binder Clips

Ruler

Sharpie marker

WAGON COMPONENTS

1- 13-1/2" x 9" x 1/2" plywood (bed of the wagon)

2- 13-1/2" x 1/2" x 1/8" pine (side bed sills)

2- 13-1/2" x 1-1/4" x 1" pine (runners)

4- 4" x 1-1/4" x 1" pine (axle holders)

1- 6" x 1-1/4" x 1" pine (tongue)

2- 6-1/2" x 1" x 3/8" pine (vertical rear rack parts)

2- 8" x 1" x 1/4" pine (horizontal rear rack parts)

2- 1/2" x 9" dowel (axles)

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

4- 1-3/8 x 3/8" PVC pipe (wheel spacers)

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

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

1- 36" x 2" x 4" (optional hay bales)

Step 1: The Deck and Undercarriage

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. A drill press will also help to make the holes for the axles perpendicular.

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

I drew lines across the top of the wagon bed. The lines are to represent the gaps between the boards. On the bottom of the deck, draw lines parallel to the sides about 2" in from the edges. These are to align the two main beams, the runners.

After drilling axle holes through the 1-1/4" sides of the axle holders, glue them to the runners, one 1-1/2" from each end. Clamp the 1" sides together. With the glue dry, glue and clamp the runners to the bed. The outside of the runners align with the lines you drew earlier. Clamp them into position and let the glue dry. Drill and countersink pilot holes and install two 1-1/2" screws in each axle holder.

Locate the bed centerline on the bottom of the bed for positioning the tongue of the wagon. Drill a 3/8" hole through the middle of the tongue about 1" from the front. Apply glue to the rear 4" of a 1" side of the tongue and clamp it the the underside of the bed, centered, so 2" extends past the front of the bed.

With all of the glue dry, on the top of the bed, locate the centerline of each runner and mark each about 1-1/2" from each end and at the center. Drill and countersink pilot holes and install three 1-1/2" screws through the bed into each runner. Drill and countersink two holes for the tongue and install screws to further secure it.

Glue and clamp the side bed sills. These help prevent the bales from sliding off.

Glue one wheel to each axle. Gently hammer the axles in so they extend all the way into the wheels. Set aside to dry.

Step 2: Finishing

Make a rough jig that will hold the vertical rear rack parts while the horizontal rear rack parts are glued to them. Make sure the vertical bottoms are even and that the horizontals are perpendicular to the verticals. I applied the glue, positioned the horizontals, and weighted them down until the glue dried.

With rear rack assembled, hold it to the rear of the assembled wagon bed to locate the centers of the ends of the runners. Mark the verticals. Drill and countersink the verticals and the runners. Apply glue and install screws to secure the rack to the bed.

Turn the wagon over on the edge of a table with the rack extending down. Insert the axles through the axle holders with the PVC spacers installed as shown in the photo. Glue and assemble the second wheel to each axle. Gently hammer the axles in as needed.

Insert the pull rope through the hole in the tongue and securely tie it using a square knot or two half hitches. Insert the other end of the rope through the PVC handle and tie it off again using a square knot or two half hitches.

I cut the hay bales from a 2" x 4", making each bale 1-7/8" wide. Rough edges were again sanded. The bales are optional.

Sign and date the bottom of your project. With parental approval, present the wagon to a small child.