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The Covered Wagon Toy Box
 
Its canvas-like top “corrals” a bunch of toys out of sight while its large diameter wooden wheels make it easy to move from room-to-room.

If you choose the latter, you'll need to drill 5/16" deep by 3/8" diameter counterbores at each screw position first, then drill your 7/64" pilot holes in the centers of these counterbores. Use a 3/8" Plug Cutter to create your plugs from a piece of scrap stock that matches your wagon wood. Remember that if your plugs are to go into the face grain of a board, they should have face grain at their tops. Likewise, if they are to go into end or edge grain wood, they should be cut accordingly for the best match.

7: Turn the assembled Box over with its top side sitting on your bench. Drop the Bottom (with attached cleats) into the Box with the cleats up, toward you. Use small C-Clamps or Handscrews to temporarily hold the bottom in position while you drill your 7/32" screw pilot holes through the Cleats and into the Box Sides and Ends as shown in the exploded diagram. Be sure to drill at a slight angle so you can easily get a grip on your screwdriver during assembly. Again, countersink all holes for the screw heads, then assemble.

8: Size your stock for the Bottom Wheel Supports (H), Front Wheel Pivot (I) and Axle Supports (J).

9: Drill a 1/4" deep by 3/4" diameter counterbore into the top center of the Front Wheel Support (H). Using the centerpoint of this counterbore as a guide, drill a 1/2" diameter through hole in this same board...and another 1/2" diameter through hole in the center of the Front Wheel Pivot as shown in the exploded diagram.

10: Draw an arc on each end of the Pivot Board, then cut on your Bandsaw and sand smooth on the Disc Sander.

11: Make the Axle Supports (J) from 1-1/2" thick stock...or from two pieces of 3/4" stock, laminated together. If you choose the later option, it would be a good idea to add some wood screws to help hold these laminations together.

NOTE: Be sure to position these laminating screws so they won't interfere with the locations of the axle or the screws that mount the Supports to the Front Wheel Pivot or Rear Wheel Support.

Remember to make the two front Supports (J) 7/8" shorter than the back ones (K) to compensate for the thickness of the Front Wheel Pivot and pivot washer. When cutting these Supports, attach each pair (front & back) together temporarily with Double Stick Tape so the profiles and hole locations will match-up perfectly.

Mount the Front Axle Supports to the Front Wheel Pivot...and the Back Axle Supports to the rear Bottom Wheel Support with three wood screws and glue. Be sure to countersink the screw heads a little deeper than normal so the screw heads on the Front assembly won't rub on the front Bottom Wheel Support when the wagon is steered.

 

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