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.
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.
Since i was using pine and it soaks up water like i sponge, 3 coats of sealer was added.
Step 3: 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
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.
Weld together the frame sections on a flat surface to ensure things end up straight.
Step 6: 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
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
Prime all parts before painting to ensure years of fun
Step 9: 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.
Some paracord was used to wrap the handle to add some comfort.
Step 11: 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
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