Follow our step-by- step instructions and get the kids to help out with making their own set of wheels.

Time to allow for this project, including paint drying is 3-4 days.

Materials Required

Timber:
75 x 50mm DAR
Two pieces 600mm for axles
One piece 600mm for foot rest
150 x 50 DAR
One piece 1200mm
200 x 25mm DAR
Two pieces 550mm for seat
Two pieces 250mm
50 x 25mm DAR
One piece 600mm for handbrake
Hardware:
Two 600mm x 13mm axles and brackets
Two 125mm wheels to fit front axles
Two 200mm wheels to fit back axles
Four split pins to fit axles
Four washers to fit axles
Four 100mm x 10mm cup head bolts
Four 10mm nuts to fit bolts
Four 10mm washers
Twelve 50mm x 1.8mm bullet head nails
Eleven 50mm x 8mm cup head bolts
Eleven 8mm nuts to fit bolts
Twelve 8mm washers
Two 50 x 6mm eye bolts
Approx 2m of rope
One 130mm x 12mm cup head bolts
Two 12mm nuts to fit bolt
Three 12mm washers

Tools Required

  • Saw
  • Drill and bits
  • Straight edge
  • Hammer
  • Marking pencil/scriber
  • Spanners
  • Ruler/measuring tape

Handy hints

Use pre-dressed timber so that you don't have to sand back any raw edges. After you've cut all the measurements, paint the pieces in the colour/colours required. An undercoat and two to three coats of high-gloss exterior enamel will protect the cart from outdoor weather conditions. Where possible all metal parts should be galvanised.

Assembly

Make sure that the front and rear timber axles match the length of the steel axles. You may need to saw off a small piece of a timber axle to adjust its length.

Front Axle

  1. Drill a 13mm hole in the centre of the timber axle. 
  2. Position the corners of the steel axle brackets so that they are located in the lower left and lower right corners of the timber axle.
  3. Use the pre-drilled holes in the steel axle brackets as guides for drilling holes for the 50mm x 8mm bolts that will secure the brackets to the timber axle.
  4. Drill 8mm holes and bolt the brackets to the timber. Ensure the flat head of the bolt is on the top outside of the axle.
  5. Drill 6mm holes for the eye bolts. Make sure the holes are clear of the steel axle brackets. Push them through and bolt them. Thread the rope through the eye bolts and secure it by tying knots either side.
  6. Insert the steel axle through the bracket and place one axle washer against the face of either bracket. You may find that a second washer will be required to help separate the wheels from the timber axle.
Assemble the front axle

 

Assemble the central board

 

Rear Axle

  1.  Position the corners of the steel axle brackets so that they are located in the lower left and lower right corners of the timber axle.
  2. Use the pre-drilled holes in the steel axle brackets as guides for drilling holes for the 50mm x 8mm bolts that will secure the brackets to the timber axle.
  3. Drill 8mm holes and bolt the brackets to the timber. Ensure the flat head of the bolt is on the top outside of the axle.
  4. Insert the steel axle through the bracket and place one axle washer against the face of either bracket. You may find that a second washer will be required to help separate the wheels from the timber axle.
Rear Axle

Centre board

  1. Position the rear axle so that its face is flush with the edge of the centre board and drill two 10mm holes through the board and axle. Push two 100mm x 10mm bolts through and bolt the axle to the centre board.
  2. The front axle should be set approximately 50mm beyond the face of the centre board. Use the previously drilled 10mm hole in the axle to mark a 10mm hole in the centre board. Insert the 100mm x 10mm cup head bolt, place a 10mm washer either side of the axle and use two nuts to lock the bolt in position. The steering mechanism is complete.

Seat

Glue and nail the seat as shown in the illustration. Position the seat so that it is 75mm away from the rear of the board. Drill two holes through the base of the seat on the board so that the 8mm bolts can be bolted in position. Make the size and position of the seat suit the age and leg length of your kids.

Glue and nail the seat

Brake

Drill a hole through the centre of the brake and through the side of the seat. From the inside of the seat push the 50mm x 8mm cup head bolt through both holes. Put a washer between the brake and the seat and between the nut and the brake. Use two nuts to lock the bolt. To operate the brake push down on the lever so the other end is forced against the rear tyre tread.

Drill a whole through the centre of the brake

Foot rest

Again, adjust the position of the foot rest to suit the billy cart's drivers. Drill and bolt with two 100mm x 10mm cup head bolts.

Drill and bolt the foot rest

 

 

Important: This instruction leaflet has been produced to provide basic information and our experienced staff are available to answer any questions you may have. However, the use of this information is on the understanding that the Home Timber and Hardware (including its author, owners and proprietors) disclaim all and any liability for any damages or other amounts found to be recoverable resulting from such information, even when given negligently or attributable directly or consequentially upon any act or omission of Home Timber and Hardware. Should Home Timber and Hardware be found liable in any way for the information provided, the user acknowledges and agrees that such liability shall be deemed null and void. The user is advised to call in a qualified tradesperson where expert advice is required.