WOODY WAGON Wiese sss ier Cut the chassis (A) from oak, to the size listed in the Bill of Materials. Sand gentle taper 1 top and bottom edges The woody shown is made Sado’ Softee taal traay sane pied ay substitute other combinations usin; x Do used 25 a.ternplate ty from Macy’s Department sti Shortly on, Lay out and drill for the four axI clerk Parts Kit mock ; . one or two shows a year. His family. in Toys to offer a parts kit that includes all 1 mount the bum Dr cluding his wife and three ind pins that you'll sponding holes in the bumpe n the Kit Source bow 1ew and improved toy ideas, And tl Knothole Toys inventory has been ex The Engine Compartment: The Chassis Whether you are building a large ca trucks and trains. carried in fine stor from coast to coast. But best Stephen seems to get every bit ayMAKING THE ENANE COMPARTMENT 1 ena Lone NEN T ooeer Cnr Step 1. Cut a pair of sides (D) from walnut, a hood (E) from walnut. and a grill (F) from oak. Glue the four pieces together. ‘Step 2. Draw an areon the top end of the gril. 10 act asa depth guide for your band saw cuts. Make a series of cuts, each about 1/ in. apart on-center from the other. Stop the cuts at the curved sept line, Step 3. Make the 13 degree taper vis along each side. Apply’ a 45 degree chamfer along the top edges ofthe ta pers. then contour the grill tp the ap- proximate shape shown, Lastly. make a series of shallow band saw kerfs in the pair of louvers (G). The safest way to do this is to use doublestick tape to tem: porarily fasten the louvers to a length of serap stock, and then make the kerfs This way your hands will be well out of the way of the blade. Remove the lou: vers and glue theft in place on the sides Of the engine compartment Also drill the pin holes in the head- lights (V), drill the corresponding in the engine compartment. and mount the headlights, The Body Next up isthe body. Cut the front (H) 0 size from ¥Js i. thick walnut. then apply a series of 45 degree bevels as indicated to serve as a transition between the body and the engine compartment. The easiest ‘way 10 do this is to hold the engine com- partment against the front and scribe the profile. Use the scribed lines as a guide for your bevel cuts. ‘Cut the back (1) from 3/s in thick oak to the dimensions shown in the Rear El- evation. Then go to work on the side panels. Each of the oak side panels is The Woodworkers JuraMayiDune 1984« The Wood orkers Journalmade up of a side (J four short rails (L M). After cuttin ue the posts and rails to the sides asin in the Side Panel Detail Once the side panels are complete. glue them, the back and front to the chassis, Also ne compart- ‘ment into place on the chassis. Make the walnut roof (N). But nove that itis not added until after the seats and steering assembly have been made and installed posts (K two long rails all the parts to size dicate le the € The Seats and Steering Assembly Each of the oak seats consists of & bottom (0) and a back (P). Cut the PartDescription Size Regd Chassis A Chassis TaxsBiex 24 B BackBumper — Sex3exedie © FrontBumper — VaxSux43e | Engine Compartment | D See Maxtax3 2 | © Hood Vaxsiex3 F Gal Saxstiax2n |G Lower Vex texta 2 Body H Front Yexsex2— 1 1 Back SexsBexse 1 | J Se x2iexsia 2 | K Post Vexdexse 6 L Shor Rai Vexdexti2 8 M Long Ral Nex3ex2 4 N oot Srexa8ex79@ 1 Seats © Botom Yaxixe 2 P Back BexiTexze 2 Fenders Q Fender Seo Fuze Pate 2 Wheels, Heelights,Pogs & Pina? R Wheel Bieda.x iti ¢ | $ Sterng Wheel 1dia.x7ire tick 1 T Steenng Column 3'6¢a.x1'/2tng 1 U Peg SeePogDeai 4 V Headight See Fullsize Pate 2 W Pen Steda.xizleng 6 * Al these pars are avalabe as akt. See Ka Souce, May/ Parts to the sizes indicated. hen use the ting a serieg of shallow kerfs with the band saw. each cut about Ws in. deep and !/s in, on-cen from the previous cut, to texture the seat surface Glue the seat parts together, then glue the seats in place to the chassis. Drill for (S) to the column, and glue t8@ assembly into the hole drilled for it into the front. Finally, add the roo! ‘The Fenders ‘The fenders (Q) are shaped from 3/+ in thick walnut. By making photocopies or using carbon paper, you should be able to transfer the fender profile from our full-size pattern to your stock. Use the band saw to cut the rough profile, then use rasps, files and sandpaper to achieve the final contours. Compare your work frequently to the photo, so your fenders look as close as possible to the original Mount the wheels first. and then the fenders. This way you can’ adjust the fender position slightly as needed to pro- around the wheels. Note as shown in the Side Elevation, that the bottom edge of the fenders isn’t flush the bottom of the chassis. but is posi tioned up about !/s in. up from this face. Finish Stephen Sutton uses a natural mineral oil finish on all his toys, acfinish that he ‘notes is safe for children, If you'd like a little higher polish use bee's wax. an- other natural substance. Avoid the use of petroleum-based finishing products, Editor's Note: This is just the first of be presented in The Woodworker's Journal. We've got more of his stunning classic cars planned for future issues, including a handsome Deux Coup in our No vember/December Christmas issue. Si Stephen Sutton’s work Kit Source: A parts kit, including the four wheels (Ry, the steering wheel (S), the steering column (T), the four pegs (U), the pair of headlights (V) and a length of 3/10 in. dowel stock suffi cient fo yield the six pins WW) is available from: Knothole Toys RD 4, Box 550 | Eggleston Hill Rd Cooperstown, NY 13326 Specify Woody Wagon Parts Kit Price per kit is $9.95 postpaid. Check ‘or money orders only. Please note, kit only inciudes part listed, not the wood forthe remaining parts