Make full size patterns from print of Grader parts by gluing to a piece of cardboard or hardboard. Cut pattern to shape. Draw shape on wood surface and locate various drill centers.
Drill 9/32″ holes for 1/4″ axles where indicated. Drill 3/8″ hole for blade turret.
Saw body from the 2x thickness material.
Round over all edges with 1/4″ round over bit.
Cut 3/8″ dowel to length and glue dowel cap on one end.
Saw blade from 1/2″ material.
Drill 3/8″ hole in top.
Round over all edges with 1/8″ round over bit.
Cut ¼” dowel for axle to length for 3 axles (axle support width + 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 spread the glue to the inside of the wheel axle hole.) Add second wheel to complete assembly. Test that wheels turn freely. Sand to ease rough or sharp edges.
Insert 3/8″ dowel with cap on top through the grader frame. Apply glue to the hole in the blade and insert the dowel. Leave 1/8″ gap between blade and floor so blade does not drag.
Rub your hands over the entire vehicle to make sure there are not sharp edges or points. Remove with sandpaper if any are found.
