This toy pattern includes a PDF scan. Please be sure to download and print the attached toy pattern at the bottom of this page along with these instructions.
Tools
- Band Saw with 1/8″ blade or Scroll saw
- Sanders – Disc, belt and spindle.
- Router with 1/4″ round over bit
- Drill Press
- Sand paper or emery boards
Material
- 2″ x 8″ lumber
- 2″ x 4″ lumber
- ¼” dowel
- bullet catches for 3/8″ hole
- 1-1/4″ wheels from the Toy Committee or make wheels with a 1-1/2″ hole saw
Instructions
- Cut a 2×8 to 12″ long to make part A. Round edges with a 1/4″ round over bit.
- Make pattern from print for the 4 Cars and the handle by gluing to a piece of cardboard. Cut pattern to shape.
- Draw shape on 2×8 surface and mark axle centers and windows. Mark cutlines as shown on the plan.
- Drill 5/16″ holes for axles and 1/2″ holes for windows.
- Cut out the cars with a band saw with 1/8″ blade or Scroll saw.
- Saw handle from 2″ x 4″ lumber (sand sides smooth). Round edges with a 1/4″ round over bit.
- Sand cut surfaces with power sanders to smooth all surfaces.
- Make wheels with a 1-1/2″ hole saw per directions on the plans or use wheels from the Toy Committee.
- If wheels are made per the plans, cut ¼” dowel to length for axles per the plan directions,
- If wheels from the Toy Committee are used, cut ¼” dowel to length (body + 2 x wheels thickness + 1/16″ or 3/32″ clearance). It is important to taper the ends of the axles to get them to easily go into the wheels. An easy way to do this is to gently sharpen the axles by turning the sharpener backwards in an old fashioned pencil sharpener-much easier than trying to do this with sand paper.) glue and clamp the carrying case back together at the entry cut. After the glue has dried, remove the clamp, then drill and peg the cutline with a 1/4″ dowel. Glue and clamp the hndle to the case and drill 1/4″ dowel mounting holes. Add a few drops of glue to each dowel hole and glue the handle in place. When dry, sand all protruding dowels flush.
- Drill 1/4″ holes for ball catches in the case. Then insert cars and mark for the catches. Drill 3/8″ holes in the cars for the ball catches. See detail on the plans. Partially fill the 1/4″ holes in the case to the point shown.
- Cut ¼” dowel to length (body + 2 x wheels thickness + 1/16″ or 3/32″ clearance). It is important to taper the ends of the axles to get them to easily go into the wheels. An easy way to do this is to gently sharpen the axles by turning the sharpener backwards in an old fashioned pencil sharpener-much easier than trying to do this with sand paper.)
- Assemble wheel to one end of axle using white or yellow glue (Hot melt will not work.) (An easy way to glue the wheels to the axle is to dip a pencil point into a pool of glue and use the pencil to add the glue to the inside of the wheel axle hole.) Add second wheel to complete assembly. Test that wheels turn freely.