July 23 - 29, 2017: Issue 322

DIY Child's Waggon

DIY Childs Waggon

You may remember the wagons of your youth. Our new Collector’s page features some of the great old ones made by Cyclops. Or you may wish to make a garden planter or a platform that makes it easier to move those great big pots that make outdoor areas look fantastic but need moving in some seasons to ensure plant health. If you want a child's toy that is suitable for outdoor use. Either way, this step by step guide will take you through all that you need to know to build your own wagon and build something that will provide years of use.

A good way to get the youngsters involved here is get them thinking about the final look for the waggon (if it's for them), or what will last longets for your use if you're modifying this base idea for using under those larger pot plants.

2 x  1.905cm x 11.43x 60.96  Side  A
2x  1.905cm x 11.43x 36.83 End  B
1 x  1.27 x 40.64 x 60.96  Plywood bottom  
2 x 1.905cmx 8.89x 30.48 Side rail  
1x  1.905cm x 11.43x 36.83 Back rail 
6x  1.27 x 4.1275 x 23.495 Batten  
8x  1.27x 6.985 x 11.43 Wheel truck  
4x 1.905cm x 1.905 x 6.985 Truck separator block 
2 x 1.905cm x 4.445x 9.525 Wheel mounting block   
1 x 1.905cm x 15.24 x 30.48 Steering yoke   
1 x  1.905cm diameter x 60.96 Dowel (handle shaft)  
1 x  3.175diameter x 12.7 Dowel (handle grip)  
4 wheels – rubber ones will last longest

4 x 0.9525-diameter x 6.35 hex-head-bolt axle 
(Note: Cut off excess; finished bolt is 6.35cm.)
8 x 1.905 cm diameter washers 
4 x  0.9525 cap nuts 
100-piece pkg 1.905 No. 6 Phillips-head wood screws 
100-piece pkg 2.54 No. 6 Phillips-head wood screws 
1 pack bright finish nails 
2 x hex nuts 
1 x 2.54 cm diameter screw eye 
1 x  1.5875 cm diameter screw eye 
16 x Finish washers 

Adhesives - Finish
600mls polyurethane, 600ml acrylic latex primer, 600mls semigloss dark red acrylic latex, wood filler, wood glue

Circular saw
Basic hand tools
Dust mask

Build the basic platform for the wagon using your pieces of cut lumber A and B. The platform here is about 40.64cm wide and 60cm long, but you can modify the size easily to fit what you want. Leave space at one end for attaching handles

Make the front axle swivel assembly by ripping two boards 5cm x 5cm, the same length as the width of your wagon.
Drill a hole in the center of these two boards for the swivel pin. 
Cut a section of pipe (or wood dowel, if preferred) 6.3cm) long to fit in the swivel assembly holes. Use a flat washer as a bushing to allow the swivel to move freely when it is assembled.
Use a large screw or lag bolt to through-bolt the swivel and hold it in place. You may find you need a large fender washer to allow the screw to tighten if the hole is so deep the wood will not hold it.

Drill the ends of the moving section of the front axle swivel assembly for the wheel bolts. A 1x 1.2cm steel bolt works well for this assembly. Drill through the center of each wheel, slide the bolt through, slide a flat washer on the bolt, then stick the bolt into the hole in the end of the axle assembly.

Drill a hole though the axle assembly and the bolt that attaches the wheel to the assembly. Install a wood screw to lock it in place. You might grease the bolt so the wheel will turn freely and to reduce wear on this surface, or you may choose to install a metal bushing in the center of the wheel to reduce wear even further. Attach the assembly to the bottom of the wagon base you started with.

Attaching the Handle
Bend two angle clips to attach the wagon handle with. Here, a 1 inch (2.5cm) by 1/8 inch (3.1mm) piece of aluminum flat stock is a good material to use, being easy to form and drill, and weather/corrosion resistant. Each side of the angle should be about 10cm long, and you will need to drill 3/16 inch (4.7mm) holes for the mounting screws on one side of each piece.

Mount these brackets at the center of the swivel/axle assembly, allowing space for the pull handle to fit between them freely. You might rip this piece of stock 3.8cm square 91cm long before mounting the attaching brackets to make sure they are positioned correctly.

Rip the stock, (described in the step, above), sand the edges smooth, and position it between the brackets so the attaching bolt can be inserted. A 6.3mm bolt 6.3cm long will hold this piece in place. You can dimple the end of the bolt where the threads come out of the nut to prevent it from loosening during use.

Build the yoke that will hold the grip at the other end of the handle. Again, the aluminum flat stock is an easy material to use for this step. Form two matching pieces in a squared zee shape (see illustration), drill it for the mounting screws, and smooth the edges with a file or sandpaper so there isn't a risk of scratches when handling it.

Fit a block of wood 2.5cm square between the ends of the yoke. Then center drill it for a 6.3mm bolt (or all thread rod) to attach it. Be sure to drill as nearly in the center as possible, using a bit long enough to drill completely through.

Thread the bolt or all-thread rod through the yoke, the handle block, and out the other side of the yoke. Then thread a nut on the end (or both, if you are using all-thread rod).

Tighten the assembly. Cut off and grind smooth any protruding bolt threads.

Assembling the Rear Axle
Build the solid rear axle. Cut a board the same length as the width of your wagon, and cut two spacer blocks to support it and allow clearance for the wheels to turn. Drill and screw the spacer blocks and rear axle into place. Then drill the ends to allow the wheel mounting bolts to be inserted. Drill and pin these bolts into place the same way you did on the swivel assembly.

Adding Sideboards and Finishing
Cut and fasten the sideboards on the wagon platform. Use wood screws or nails to attach these sides.
Sand any rough or splintery edges with a power sander or sandpaper. Be especially careful if this wagon will be used by a child.

Some Specials From Current Get In And Get It Sorted Catalogue - On Sale Until July 30th, 2017

Multi-surface preparation in one step. White base. 

Satin or high gloss. White.
Also available - 10L: $170.00 

Hook and loop. Triangular base (96mm). Built-in dust extraction. Corded

82mm. Planing depth 2mm. Batteries and Chargers Sold Separately Unless Specified 

Bonus Sander via Redemption** 
Easy tool-less blade change.  Anti-vibration counter mechanism. Moulded carry case. Corded
**Redemption website: guaranteedtough.com.au. Terms and conditions guaranteedtough.com.au/terms-conditions
Offer available 1st July – 30th September 2017. 

Superior fit and comfort.  Includes filters.  Provides protection against dust, mists, fumes and sprays. 

Includes Hammer Drill DHP453, Impact Driver DTD152, 2 x 3.0Ah Li-Ion Battery with fuel guage, standard charger and carry case. 

WINE BARREL PLANTER: $29.95 to $59.95
Fibre clay construction. 
Small:24(H)x 36.5(DIA)cm
Large: 37(H) x 56(DIA)cm 

Johnson Brothers Mitre 10 New Store
73 Bassett Street
Mona Vale - Online Store: Jbhmv.Com.Au

Products advice is available from the trained friendly staff at Narrabeen, Mona Vale and Avalon Johnson Brothers Mitre 10. 

Click on logo to visit Johnson Brothers Mitre 10 website

Johnson Bros Mitre 10 - Avalon            (02) 9918 3315

Johnson Bros Mitre 10 - Mona Vale     (02) 9999 3340

JBH Timber & Building Supplies          (02) 9999 0333

JBH Fencing & Landscape Supplies    (02) 9970 6333

www.johnsonbros.com.au Online store: jbhmv.com.au

All information and tips in this publication are of a general nature only and neither Johnson Brothers Mitre 10 or Pittwater Online News does not warrant the accuracy or completeness of the information and tips in this publication. This publication is not intended to be a substitute for expert advice. Johnson Brothers Mitre 10 advises you to always consult an experienced and qualified person when undertaking jobs of this kind (including consulting a qualified tradesperson such as an electrician or plumber where relevant expert services are required). 

You should also consider any safety precautions that may be necessary when undertaking the work described in this publication (including wearing any necessary safety equipment such as safety glasses, goggles or ear protectors or hard hats). The information and tips in this publication are provided on the basis that Johnson Brothers Mitre 10 and Pittwater Online News excludes all liability for any loss or damage which is suffered or incurred (including, but not limited to, indirect and consequential loss or damage and whether or not such loss or damage could have been foreseen) for any personal injury or damage to property whatsoever resulting from the use of the information and tips in this publication. 

Pittwater Online News and Johnson Brothers Mitre 10 also advises there may be laws, regulations or by-laws with which you must comply when undertaking the work described in this publication. You should obtain all necessary permissions and permits from council and/or any other relevant statutory body or authority before carrying out any work. Major projects published in this publication always list these and/orlinks to where you may research what your own project requires to meet regulations.

Previous DIY Pages:

Decking Timbers  Caring For Your Deck Decking Finishes  Privacy Screens I Privacy Screens II  Privacy Screening Hardwoods  Autumn Paths and Lawns  Insulation Batts Plasterboard  Ventilation - Edmond's Ecofan Blackboards for Children and Home Spring Lawn Care Shade Sails & Watering  Basic DIY Tools DIY Tools - Power Drills Recycle Your Trampoline into An Air Bed  How to Build Your Own Backyard Cricket Pitch Christmas Lights Displays around House and Garden Summer Mildew - Refresh, Renew How to Fix Things That Drip and Bump in the Night Time To Plant Winter Vegetables in  a Raised Garden Beds Layout Organsing Your Tool Shed  Make Your Own Weathervane Installing A Garden Watering System  Decking Oils  How To Make Garden Compost  How To Winter proof Your Lawn How to create Shabby Chic effect on Timber Furniture How to Build Your Own Raised Garden Bed  Growing Your Own Winter Vegies Winter Heating Guide Prepare Your Yard For Winter Eradicating Noxious Weeds From Your Yard How to Fix Furniture Finishes Part I How to Repair Scratches, Dings, and Dents of Furniture Surfaces - Part II Winter Draughts Fix  Classic Wooden Tool Carrier Spring Garden Checklist Part I  Install Your Own Skylight  Retaining Walls for Saving Soil and New Spring Garden Beds  Summer Salad Garden Native Plant Garden for A Fairy Arbour Renewing Short Flight of Exterior Stairs Deck Maintenance DIY Summer Tasks You Can Do In Time to Get to the Beach  Garden Ponds for Attracting Birdlife, Dragonflies and for the Soothing Sounds of Water  Salt Air: Maintenance and Protection Creating an Outdoor Dining Arbour, Gazebo or Patio - Part I Creating an Outdor Dining Arbour, Gazebo or Patio Part II Autumn Garden Tasks  Autumn DIY Jobs: Waterproof Your Home Checklist  Dealing With Dampness Inside the Home  Fixing Your Fence  Repairing and Replacing Damaged Decking boards  DIY Toy Box and Snow Globes: School Holidays Fun - Winter 2015  DIY Wooden Toy Cars and Perfect Painted Flowerpots: School Holiday Fun - Winter 2015  Shoring Up an Under House Earth Bank – Installing a Basic Retaining Wall  DIY One Shelf Sideboard  Early Spring 2015 Garden Care Salad Garden For Children  Keeping Your Garden and Home Cool in Hot Weather  Classic Beach Garden and Camping Chairs 3 Portable Versions Anyone Can Make DIY Outdoor Furniture Mark I: Park Benches for Your Garden Make Your Own Scooter or Skateboard: Summer 2016 Fun  How to Install a Solid Core Door and Door Furniture  Summer Garden Jobs: Pruning A Hedge  How to Make A Swing Chair - With A Frame for Garden Setting  Garden Jobs for March to Make A Beautiful and Healthy Spring  Keeping Outdoor Nooks Warm During Cooler Months  Children’s Step Stool with Storage  Stop Winter Rain Lawn Loss and Soil Erosion on Slopes  DIY Garden Shed: Part 1 of 4 - Base  DIY Garden Shed: Part 2 - Framing Walls  DIY Garden Shed: Part 2b - Gable Roof Framing  Garden Shed Part 3: Roof Installation  DIY Garden Shed: Weather- boards - Door And Window Installation And Paint Finish DIY Coffee Table With Chessboard Inlay  Spring Gardening: Feeding Your Soil And Plants - What Works For Each Plant  DIY Sandstone Flagging Parking Area - Platform  DIY Pre-Summer Checklist For A Safe Home   Summer Spruce Up: Interior Paint Tips and Three easy steps to rejuvenate your timber deck The Perfect BBQ Garden Setting DIY Water Wise Garden   DIY Side Gates  DIY Storm Preparation And Home Protection  One To Two Day DIY Weekend Spruce Ups  Vegepods For Autumn Planting + Easy To Make Lego Table Or Student Desk That Can Be Dismantled + Johnson Brothers Mitre 10 Online Store   Johnson Brothers Mitre 10 Great New Mona Vale Store: Still In Bassett Street - number 73  Johnson Brothers Mitre 10 New Mona Vale Store: The Greenlife Garden Centre  Go Outside And Play: Creating Garden Spaces To Connect Children With Nature DIY Plasterboard Repair DIY Dolls House Or Garage Or Boatshed  


John and Bob Johnson - The Johnson Brothers Profile  John William Alfred Johnson - The Eulogies for those who could not attend Mass

Australia's Prime Minister Visits Mackellar - Informal Afternoon Tea with Hon. Malcolm Turnbull October 2016