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Games & Toys
How to make a toy wagon
How to make a toy wagon
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Overview
This cute timber child's toy wagon is lightweight but sturdily built. A plywood box with off-the-shelf wheels and axles, it’s an easy weekend project.
Made from plywood, it features fixed handles with a dowel handlebar, and rubber wheels with a 30kg load capacity. If you have the plywood cut in store, it’s easier to transport home and saves you needing a circular saw – so a drill is the only power tool you’ll require for this project.
For the finish we went for zebra stripes, but choose your kids’ fave pattern or design. And, for an extra touch of fun, attach colour-changing ‘headlights’ to the front.
Tip: Always wear the appropriate safety equipment (safety glasses, gloves, ear muffs and a mask, for example) and always follow the instructions for the product or equipment.
Tools and materials
- Artist's paintbrush
- Black two-in-one decor paint and sealer
- Combination square
- Double-sided adhesive strips
- Drill with 6G countersinking, driver and 2.5mm bits
- Drop sheet
- Hacksaw
- Lint-free cloth
- Mitre box and handsaw
- Painter's tape
- Puck lights
- Quick-grip clamps
- Tape measure and pencil
- Timber filler with scraper
- White self-priming exterior paint
- Woodworking adhesive
- 1200mm x 1198mm x 12mm plywood
- 1.8m x 42mm x 19mm DAR pine•
- 6G x 30mm timber screws
- 180-grit abrasive paper with sanding block
- 8G x 30mm button head screws
Steps
Cutting list
From 12mm plywood:
- Sides: 500mm x 200mm (2)
- Ends: 330mm x 200mm (2)
- Base: 500mm x 350mm
Cut the timber
Follow the cutting list (above) to have the plywood cut in store. Measure and mark 19mm pine, then use a mitre box with a handsaw to cut two 520mm handles, with one end of each at a 22.5-degree angle, and four 55mm-long blocks. Cut a 350mm bar from dowel. Sand cut edges, then all over; wipe away dust.
Build the wagon
On the side pieces, use a combination square to mark 6mm in from the ends, to predrill three evenly spaced holes with a countersinking bit. Position the sides against the end pieces, apply adhesive and secure with 30mm screws. Position the base with edges flush and predrill evenly spaced holes; secure with adhesive and screws.
Make the handles
On the handles, mark a hole centred 25mm from the straight ends and predrill. On the ends of the bar, mark the centres to drill holes with a 2.5mm bit. Position the handles against the bar; apply adhesive and secure through the holes with screws. Smooth filler over the screws, leave to dry; sand off excess and wipe away dust with a damp cloth.
Attach the handles
Apply two coats of self-priming paint to the wagon, handle assembly and blocks, leaving to dry after each coat. On both sides of the wagon, measure 100mm in from the end to position the angled handles flush with the base and aligned with the top corners. Predrill 25mm from base and top edge of the box; secure with adhesive and screws.
Paint the pattern
Mask off the handles with painter’s tape, then draw zebra stripes around the wagon. Use an artist’s brush to apply two coats of black paint to the stripes, leaving to dry after each coat. Secure the blocks inside each corner with adhesive; leave to dry. Tip: The blocks add reinforcement for the wheel brackets.
Add the finishing touches
Tape the adjustable axles to mark 350mm; cut using a mitre box with the hacksaw. Smooth off burrs with a metal file. Attach the supplied brackets, wheels and supplied caps. Position the brackets on the wagon base, flush with the sides and 10mm from the ends; secure with button head screws. Add puck lights to the front with adhesive strips.
Keep in mind...
- When using power tools, always protect ears and eyes with ear muffs and safety glasses (gloves and mask are also recommended), follow the manufacturer’s instructions and work in a well-ventilated area.
- For painting, always wear safety equipment (eye protection and mask) and ensure the work area is well ventilated. Keep all paint and chemicals out of reach of children and pets.
- This wagon is designed for transporting toys and games and is not for riding in; when not in use, store indoors or undercover.
- Paint colours may vary on application.
Looking for more kid-friendly D.I.Y. projects to make?
Check out our article on how to make a play table for kids.
Photo credit: Martina Gemmola, Carly Spooner.
[disclaimers]
Some advertised services and products are not available at some Bunnings stores, but products can be ordered.
*Timbers vary by state and territory; contact your local store for further information
More D.I.Y. Advice
Health & Safety
Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.
When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.