Build a wagon


Construction manual for a wooden wagon

Build a wagon: wagon

Wagon-building instructions Festool: Father's Day or hike with the kids, a wagon is the ideal workhorse for leisure activities. In order to breathe new life into this vehicle, with its slightly dusty image, Festool has come up with a new design with practical storage options.

And the best part is: Building a wagon is child's play. The number of wheels has shrunk from four to three to make the car more manoeuvrable. The center of gravity has moved far downwards for a high tipping stability. Due to the large rear wheels, the car has a good off-road capability. On the front there is a drink holder, behind is a trunk with cover. If this cover is folded forward and locked, creates a seat for the children. With only 15mm thick body material, the body is light yet sturdy. The wheels and axles are available from specialist dealers or DIY stores. Care must be taken when building a wagon to use models with rolling or better ball bearings. The connections are screwed open and are filled before painting. An elastic drawbar made of ash wood and a stainless steel or wooden handle complete the appearance of the Bollerwagens.

material list

Pos.Num.designationlengthwidththicknessmaterialcomment
12page100035015bfu
21ground80042015bfu1 x 16 degrees
31bulkhead42035215bfu2 x 16 degrees
41center wall42019015bfu1 x 16 degrees
52rear wall4209015bfu1 x 32 degrees
61bottle Cage42015015bfu1 x 16 degrees
72Mudguard long23010015bfu1 x 37 degrees
82Fender short14010015bfu1 x 37 degrees
92Pads trunkabout 195about 19515bfu
102backrest41827015bfu1 x 16 degrees
112Strut backrest100about 13015bfu
122Pad seat1503015bfu
131Bracket steering head42019025multiplex
141crown25017525multiplex
152forkleg19015025multiplex
161shaft9653030ash-tree
171Handle330d = 20beech
184Body washers M10d = 50
192Washers M10
202Body washers M10d = 25Brass
211Machine screws M1070
221Machine screws M10110
232Schubkarrenradd = 400
241Sackkarrenradd = 260
251axis670d = 20
261axis175d = 20
274Achsklemmen
284hubcaps
292Hinge (backrest)6030
302Latch (backrest)

(All dimensions in millimeters)

equipment

  • table saw
  • Possibly. Handkreissäge
  • jigsaw
  • Cordless Screwdriver
  • Random Orbit Sander
  • Possibly. belt sander

tool list

  • rubber hammer
  • compasses
  • sanding block
  • To force
  • hacksaw
  • iron filings
  • Drill 20 mm
  • Drill 10 mm
  • Drill 8 mm
  • Drill 4.5 mm
  • Drill 3.5 mm

building instructions

Build a wagon: item

Saw wood panels

The individual panels are cut to the dimensions specified in the wagon assembly instructions. The positions 2, 3, 4, 6 and 10 are sawed off at one or both edges with a slope of 16 degrees. To do this, set the hand or table saw to the correct angle and saw off the individual plates.

Build a wagon: item

round off the corners

Positions 1, 6, 10 and 13 have to be rounded off now. These curves are drawn with a compass or a string. To be able to saw clean curves with the jigsaw, you must use a sharp curve saw blade.

Sawing cutouts

Build a wagon: screw

The recess at the front will complete with the jigsaw or a circular saw and matching guide rail sawn into the sides (item 1). When using a circular saw only the corner with the jigsaw must be cut out.

Grind woods

The parts with the same rounding become clamped together and the contour ground.

Build a wagon: wagon

For this you use a compass, to mark the holes on the bottle holder (item 6 of the wagon assembly instructions).

The holes are sawed out with the jigsaw. In order to be able to immerse with the saw blade in the material, you can first drill a hole with 8 mm diameter in each circle.

Saw holes

Build a wagon: screw

The holes (d = 20 mm) for the axles are drilled in the sides (item 1) and in the spars of the steering head (item 15) - in the positions 13 and 14 the holes (d = 10 mm) for the axis of rotation. When building the Bollerwages often vertical drilling must be carried out. It is best to use a drill stand or a stand drill. At the upper edge of the middle wall (item 4) two cut-outs for the bands have to be cut.

Build a wagon: holes

Cut recesses

The width of the recess corresponds to the length of the bands, the depth corresponds to the height of the folded band. On the side supports of the trunk lid (item 9) still cutouts must be cut, in which the bars can disappear to lock the backrest. This is best done with the jigsaw.

Build a wagon: screw

Pre-drill screw holes

In all joints you should, in addition to screwing, still use waterproof glue. The two parts of the backrest (item 10) are screwed together at the lower edge. First, the screw holes (d = 3.5 mm) should be drilled in the vertical of the two parts. Then you can hold the parts together and screw them together.

Build a wagon: item

Mark positions

On the inner surface of a page need the positions of the items and the screw holes are marked. Now you can clamp the two parts together and pre-drill the holes with a 3.5 mm drill bit. If a countersink with depth stop is used, the drilling depth must be set so that a visible depression is created on the second side and the hole can be drilled at this point.

Build a wagon: item

Sand inner sides

Before gluing you have to sand the inside surfaces, because these are difficult to reach later. The sides and the bottom are clamped and aligned with clamps. Now you can screw these three parts together. Then, each item can be screwed to the finished body gradually.

Build a wagon: item

Saw grooves

The steering head consists of three parts. First, the two fork legs (Item 15) are sawn. The fork bridge (Pos. 14) is a rectangular board. On the underside you saw with the table saw two grooves, in which you put the spars. To determine the exact position of the groove, the wheel is held together with the two clamping rings and measured through the axle hole the exact width.

Build a wagon: wagon

Cut out grooves

This width is the distance between the two grooves. The groove width corresponds to the thickness of the fork legs. By adjusting the stop on the table saw, the grooves are cut out cut by cut. To be able to saw the recess for the drawbar (item 16), first measure the width of the drawbar plus two M10 washers (item 20). When building the Bollerwagens must always be worked exactly, otherwise there are problems when composing give.

Build a wagon: build

Cut out curves

The required width is marked on the fork bridge and sawed out the recess. Become lateral Notches cut into the bridge. To mark the rounding, you can use a round container. For cutting, it is best to take the jigsaw.

Build a wagon: build

Use dowel template

The axis of rotation for the drawbar is drilled from both sides into the fork bridge with a 10 mm drill bit. To drill exactly vertically, you should use a dowel template to help. All parts of the steering head are rounded off with a milling cutter or a sanding block. Then you can pre-drill the screw holes (d = 4.5 mm) and screw them together with the steering head.

Build a wagon: wagon

Saw off boards

The boards for the mudguards (items 7 and 8) will be sawed off obliquely and rounded. For glueing both boards are first placed with the underside and connected on the top exactly at the impact with tape.

Glue thoroughly

Build a wagon: item

Then turn them over and add glue to the pile. With another strip of tape will be everything clamped after folding. All visible edges must be rounded off generously. In the backrest you screwed a stiffener (item 11) on each side.

Mount axles and wheels

Build a wagon: build

All surfaces must now be sanded off. On the back of the backrest are in the assembled state the bolts screwed on and holes drilled in the side for locking.

For final assembly First fit the two axles and then the wheels. They are secured against slipping with axle clamps which are fastened to the axle by means of a grub screw.

Build a wagon: item

Mount wheel cap

As conclusion comes still a hubcap on the outside. The steering head and drawbar are mounted to the body and the mudguards are screwed tight. Then you can screw on the backrest and the two bolts. All screw connections and latches must be smooth.

Build a wagon: item

Retighten machine screws

If too much paint has run into a hole, you drill this out before mounting. The machine screws must be tightened after the first use, as the washers at the beginning still press into the wood. The instructions for colored design of the car can be found in the surface tip.

Tip surface

Build a wagon: build

First, the wagon is disassembled back into the individual modules. Then you fill the visible screw holes with polyester spatula (car trowel) and carefully wipes off the dry putty.

For a clean trowelled surface are actually always two putty passages needed but this is not a problem due to the very fast drying time of the putty. Then, when everything is smoothed, you have to worry about which part should get which color. Then the items can be painted with a brush.

Build a wagon: holes

After the first strike must a so-called intermediate grinding With sandpaper (P240 grain size), the second coat of paint is applied. Suitable colors are opaque acrylic or synthetic resin coatings, but also the car paint from the tin or opaque glazes on a biological basis.

To be able to apply graphics later, one manufactures simple stencils made of cardboard and spray the free spaces with the spray can. With a waterproof felt pen, the transitions can then be provided with more contrast.

Build a wagon: wagon

Build a wagon: build

building plan

Build a wagon: wagon

Courtesy of Festool.

Photo credit

All photos: © Festool

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