Radio Flyer DIY Wagon




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  1. #1
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    Default Radio Flyer DIY Wagon

    So I thought I'll quickly do a DIY kiddies wagon thread.

    It was my sons 2nd bday this weekend and he had a plastic wagon that was getting a bit small for him. Seeing that I was always amused by these American Radio Flyer wagons that they use to strap to the roof of the Beetle's I thought why not build him a bigger one.

    So here it goes.
    This is what I saw on the Radio Flyer Website
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    This is the design that I came up with, using std wood sizes.

    Click image for larger version. 

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  2. #2
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    Default Re: Radio Flyer DIY Wagon

    So I went to the local Builders that I hate, but anyway, I don't have time to go the proper wood merchants.
    Click image for larger version. 

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    Stock
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    Started Cutting Pieces
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    Made the handle from copper tube. I actually saw somebody on the web that did this and thought that's pretty cool.
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  3. #3
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    More pieces cut and mock-up assembly.
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    Other side of handle, sealed.
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    More pieces cut and mock-up.
    Click image for larger version. 

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  4. #4
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    Sprayed the tube, Sanded, Sealed the wood and dummy assembled the first axle.
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    Second axle assembly started.
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    Still need to put end stops on both sides of the wheels.
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  5. #5
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    Thought I would play a bit and engrave his nickname on the side of the wagon.
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    Glued and clamped mock-up
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    Some final sanding
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    Final color spray, and ready for sealer and rear axle fitment.
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  7. #6
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    First and second coat of sealer done.

    Click image for larger version. 

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    Added a plywood spacer to the rear wheel assembly to make up for the height of the front swivel part.
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    Front assembly mock-up, without the steering beam.
    Click image for larger version. 

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    Got this swivel from Gelmar, so I'll see how that holds up.
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  9. #7
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    Default Re: Radio Flyer DIY Wagon

    Viper, what is the dimensions of that swivel?
    I am planning a Murphy bed, and on the websites they show this for the pivot point.
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  10. #8
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    Default Re: Radio Flyer DIY Wagon

    Quote Originally Posted by leonoost View Post
    Viper, what is the dimensions of that swivel?
    I am planning a Murphy bed, and on the websites they show this for the pivot point.
    It's 76x76, they also have a 150x150
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  12. #9
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    Dummy Mock-up again
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    Swivel work, getting checked.
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    Working on the Handle location.
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    Structural Test - passed.
    Last edited by ViperR; 2018/09/14 at 08:17 AM.
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  13. #10
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    Default Re: Radio Flyer DIY Wagon

    Well done!
    There is more value in that wagon than anything you can buy!
    (It is measured in love, not rands)
    "Nothing in the world is more dangerous than sincere ignorance and conscientious stupidity" - Martin Luther king Jr

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  15. #11
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    Default Re: Radio Flyer DIY Wagon

    Click image for larger version. 

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    Final product

    Next - need to get approval from mini me.
    - Still need to make the cattle rails.
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  17. #12
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    Default Re: Radio Flyer DIY Wagon

    Really really nice. Love the copper pipe idea.
    Jan
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  18. #13
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    Default Re: Radio Flyer DIY Wagon

    The Manager did a quality check. He was not happy with this swivel It only lasted about 30min.
    Click image for larger version. 

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    The problem is that he sheet metal is so thin that when he pushes or pulls the wagon the plate starts flexing. Eventually the bearing started to fall out.

    So not being a huge problem, I made a plan now we have this.
    Click image for larger version. 

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    M12 Carriage bolt with two oversized washers and a nyloc nut.
    He'll definitely won't break this swivel. I was initially a bit worried that it will be a bid too hard to turn but actually it work pretty well. I just put a bit of grease between the two washers.
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