How to Build Your Own Kid's Wagon

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Last Updated: November 30, 2023

You may remember the Red Ryder wagons of your youth. Or you may wish to make a garden planter or kid's toy that is suitable for outdoor use. Either way, this tutorial will take you through all that you need to know to build your own kid's wagon.

Method 1

Method 1 of 6:

Obtaining Materials

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1
Assemble the materials and tools you will need. For the project in the illustrations, rough sawn treated yellow pine privacy fence boards were used because they are inexpensive and lightweight. They also resist rot and insect damage, making it suitable for use as a planter box. You will also need:
- Drill and circular saw
- Corrosion resistant screws
- Basic hand tools

Method 2

Method 2 of 6:

Building the Platform

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The platform shown in the illustrations is about 18 inches (45.7cm) wide and 24 inches (60cm) long, but you can modify the size easily to fit your needs.^{[1]
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Then scribe a circle on them, and cut them out with a jigsaw or bandsaw. Drill a 1/2 inch (1.2cm) hole in the center of each for the mounting bolts (described later).

Method 3

Method 3 of 6:

Making the Front Axle Swivel

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Make the front axle swivel assembly by ripping two boards 2 X 2 inches (5cm x 5cm), the same length as the width of your wagon.
The illustrations show using a piece of metal pipe 3/4 inches (1.9cm) in diameter, so a 3/4 inch hole is drilled for this purpose.
Use a flat washer as a bushing to allow the swivel to move freely when it is assembled.
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.
A 1/2 inch (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.
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.

Method 4

Method 4 of 6:

Attaching the Handle

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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 4 inches (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 (1 1/2 inches (3.8cm) square by 3 feet (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 1/4 inch (6.3mm) bolt 2 1/2 inches (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.
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.^{[2]
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Then center drill it for a 1/4 inch (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.
Then thread a nut on the end (or both, if you are using all-thread rod).^{[3]
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Cut off and grind smooth any protruding bolt threads.

Method 5

Method 5 of 6:

Assembling the Rear Axle

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Cut a 1 1/2 by 1 1/2 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.
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.

Method 6

Method 6 of 6:

Adding Sideboards and Finishing

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Use wood screws or brad nails to attach these sides.
Be especially careful if this wagon will be used by a child.^{[4]
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Community Q&A

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Question

I'm only 10. Is there a way I could use a cardboard box?

Community Answer

Your probably shouldn't use a cardboard box for this, because it will not be not sturdy enough and would break very easily. Instead, ask your parents if they can help you build a wagon at a time when they are not busy. If that doesn't work out, you can ask an older relative or friend.

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Can I have my 11 siblings help me?

CrazyGirl4

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Of course. If there are any little ones maybe they should not help, and maybe not all 11 at once as that could get chaotic.

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Tips

Use rust-resistant fasteners (and waterproof glue, if desired).

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Use chromed blind nuts or self-locking nuts to give the handle part a neater look,(optional).

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Battery drills and power screwdrivers or an impact driver make the assembly much easier.

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Warnings

Wear safety glasses when drilling metal and sawing wood or metal.

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Watch for sharp edges or splinters in the finished wagon, especially if it is to be used by kids.

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