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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.

12: Cut out the Pull Handle Stem (S) and Pivot Block Stem (R) as described in the List of Materials. As with the Axle Supports, these can be made with 1-1/2" thick stock or with two pieces of 3/4" stock laminated together. In fact, we recommend that you use this lamination procedure when making the Pivot Block Stem (R)...alternating the grain directions of the two layers for added strength.

Cut out the front joint and rear pivot bolt cutout on the Pivot Block Stem (R) using your Bandsaw. Be sure to leave enough clearance to get a socket wrench around the Pivot Bolt Nut. Insert and glue the cross dowel (T) to the Handle. Insert the Joint Dowel (Q) through the Pivot Block Stem and Handle and glue just the ends...being careful not to get any glue on the dowel where it passes through the Handle.

13: Cut and assemble the parts for the Canopy Frame (O & P). Cut the Canopy Lattice Slats (N) and place them in a shower with hot running water for about 15 minutes to soften them up. Attach the Strips to the assembled Frame with screws (NO GLUE) as shown in the exploded view and allow to dry thoroughly for 24 to 48 hours.

14: Make the wheels. Begin by laminating and gluing four pieces of stock together for each wheel as shown in Figure 2. It's best to use pieces of stock that are no wider than 6" and position your pieces with their grain running in alternating directions.

NOTE: The wheels need to be made from laminated stock to provide thickness and strength, as well as to prevent warpage.

Once your glued-up wheel stock has dried thoroughly, use your Bandsaw with a Circle-Cutting Jig to cut out the 11-1/4" diameter wheels. Use a similar setup to disc sand the wheel edges.

Drill a 3/8" diameter center hole through each wheel for the axles. When drilling, remember that it's best not to drill all the way through in a single pass. Rather, drill through from one side until the tip of your brad point bit just begins to penetrate the opposite side. Then turn the wheel over and finish your holes from the opposite side to eliminate any possible tear-out.

Once the wheels are cut, use an old bicycle innertube or a Shopsmith Bandsaw Tire to cover the wheel edges.

 

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