build carts - for young and old

Blueprint for a wagon of wood

build carts - for young and old

Wagon-building instructions Festool: Father's Day or walk with the children, a cart is the ideal workhorse for recreation. To this vehicle, breathe new life into the somewhat angestaubtem Image, Festool has come up with a new design with practical storage options. And the best part is: to build a wagon is incredibly easy. The number of wheels has shrunk from four to three to make the car more agile. The focus, for a high level of stability, wandered far down. Through the large rear wheels of the car has a good off-road capability. On the front there is a cup holder, rear is a trunk with cover. Will this cover folded forward and locked, creating a seat for the children. With only 15 mm thick material for the body, the body is light, yet stable. The wheels and axles are available in stores or hardware stores. it must be ensured that models with roller or ball bearings better used to build at the carts. The connections are open screwed and plastered before painting. An elastic tongue of ash and a stainless steel or wooden handle round off the appearance of Bollerwagens.

Contents build on carts

  • material list
  • equipment
  • tool list
  • building instructions
  • Tip surface
  • building plan

material list

Pos. Num. Description Length Width Thickness Material Remarks
1 2 page 1000 350 15 bfu
2 1 ground 800 420 15 bfu 1 x 16 ° C
3 1 bulkhead 420 352 15 bfu 2 x 16 °
4 1 center wall 420 190 15 bfu 1 x 16 ° C
5 2 rear wall 420 90 15 bfu 1 x 32 °
6 1 bottle Cage 420 150 15 bfu 1 x 16 ° C
7 2 Fender long 230 100 15 bfu 1 x 37 °
8th 2 Fender short 140 100 15 bfu 1 x 37 °
9 2 Requirements trunk about 195 about 195 15 bfu
10 2 backrest 418 270 15 bfu 1 x 16 ° C
11 2 Strut back 100 130 15 bfu
12 2 Pad seat 150 30 15 bfu
13 1 Mount steering head 420 190 25 multiplex
14 1 crown 250 175 25 multiplex
15 2 forkleg 190 150 25 multiplex
16 1 shaft 965 30 30 ash-tree
17 1 Handle 330 d = 20 beech
18 4 Washers M10 d = 50
19 2 washers M10
20 2 Washers M10 d = 25 Brass
21 1 Machine screws M10 70
22 1 Machine screws M10 110
23 2 Schubkarrenrad d = 400
24 1 Sackkarrenrad d = 260
25 1 axis 670 d = 20
26 1 axis 175 d = 20
27 4 Achsklemmen
28 4 hubcaps
29 2 Hinge (back) 60 30
30 2 Riegel (back)

All dimensions in millimeters


  • table saw
  • Possibly. Handkreissäge
  • jigsaw
  • Cordless Screwdriver
  • Random Orbit Sander
  • Possibly. belt sander

tool list

  • rubber hammer
  • compasses
  • sanding block
  • To force
  • hacksaw
  • iron filings
  • Drill 20 mm
  • Drill 10 mm
  • Drills 8 mm
  • Drill 4.5 mm
  • Drill 3.5 mm

building instructions

build carts - for young and old

size Cutting wood panels

The individual panels are cut to the specified in the wagon-building instructions extent. The positions 2, 3, 4, 6 and 10 is sawn off at one or both edges with a slope of 16 degrees. For this purpose the hand or the table saw to the appropriate angle is set and the individual plates sawn off.

build carts - for young and old

round off the corners

Positions 1, 6, 10 and 13 it is necessary to round off now. These curves are drawn with a compass or a string. To cut with the jigsaw clean curves, one must use a sharp curved saw blade.

build carts - for young and old

sawing recesses

The hole in the front is cut completely with the jigsaw or circular saw and matching guide rail in the sides (Pos. 1). When using a portable circular saw only the corner must be cut out with a jigsaw.

build carts - for young and old

sanding wood

The parts with the same rounding are clamped together and ground contour. For this, one uses a compass to draw on the bottle holder (pos. 6 of the wagon-building instructions) the holes. The holes are cut out with a jigsaw. To delve into the material with the saw blade, you can previously drill a hole 8 mm diameter in each circle.

build carts - for young and old

Saw out holes

In the sides (Pos. 1) and in the uprights of the steering head (Pos. 15), the holes (d = 20 mm) drilled for receiving the axles - in the positions 13 and 14, the holes (d = 10 mm) for the axis of rotation. During the construction of Boller Wages vertical holes must often be performed. For it is best to use a drill or a drill press. two recesses must be cut for the bands at the top edge of the center wall (Pos. 4).

build carts - for young and old

cut notches

The width of the recess corresponds to the length of the strips, the depth corresponding to the height of the folded tape. On the side pads of the boot lid (Pos. 9) still have to be cut recesses in which the latch for locking the backrest can disappear. For this is best to use the jigsaw.

build carts - for young and old

Pre-drill screw holes

In all connections should, in addition to bolting, still use waterproof glue. The two parts of the backrest (pos. 10) are screwed together at the bottom edge. First, the screw holes (d = 3.5 mm) should be drilled in the perpendicular bisector of the two parts. Then you can hold the parts together and screw them together.

build carts - for young and old

prefigure positions

On the inner surface of a side the positions of the items and the screw holes must be marked. Now one can together span the two parts and pre-drill with a 3.5 mm drill the holes. If one Countersink be used with depth stop, the drilling depth has to be set so that a visible depression is created on the second side and the hole can be drilled at this point.

build carts - for young and old

Grind insides

Before gluing it is necessary to grind the inner surfaces, as these are difficult to reach later. The sides and bottom are clamped together with clamps and aligned. Now you can screw the three parts together. Then can gradually be screwed to each item to the finished body.

build carts - for young and old

sawing grooves

The headset consists of three parts. First, the two fork legs (pos. 15) are sawn. The fork bridge (pos. 14) is a rectangular board. On the underside is cut with the circular table saw a two grooves into which one puts the spars. To determine the exact position of the groove, the wheel will hold together with the two clamping rings and measured by the axle hole, the exact width.

build carts - for young and old

Grooves cut out

This width is the distance between the two grooves. The groove width corresponds to the thickness of the fork legs. By adjusting the stop at the table saw cut to be cut out for the grooves cut. In order to saw the recess for the drawbar (Pos. 16), one first has the width of the pole plus two M10 washers (pos. 20) measure. During the construction of Bollerwagens always necessary to work exactly as otherwise there will be problems when put together.

build carts - for young and old

cut curves

The width needed is marked on the fork bridge and cut out the recess. The side recesses are cut in the bridge. To draw the curve, you can use a round container. best to take the jigsaw to cut out.

build carts - for young and old

use dowels template

The axis of rotation for the tow bar is drilled with a 10 mm drill from both sides in the fork bridge. To drill exactly vertical, one should take a dowel template to help. All parts of the steering head are rounded off with a cutter or a sanding block. Then one can the screw holes (d = 4.5 mm) and pre-drill screw together with the steering head.

build carts - for young and old

Saw off boards

The boards for the protective plates (pos. 7 and 8) are obliquely sawn off and rounded. For gluing both boards are first placed with the bottom and accurately connected to the top at the joint with adhesive tape.

build carts - for young and old

glue thoroughly

Then she turns around and shows at the push of glue. With a further strip of adhesive tape everything is tightened after folding. All visible edges have to be rounded generous. In the back you can still (11 pos.) Screwed a stiffener on each side.

build carts - for young and old

mount axles and wheels

All surfaces you have to grind now. On the back of the backrest, the bolt can be screwed in the mounted state and the holes drilled in the side for locking. For final assembly, first one and then mounted the two axes, the wheels. Against slipping they are secured with Achsklemmen, which are mounted on the axle by means of a grub screw.

build carts - for young and old

fit the wheel cap

As a conclusion nor a hubcap is outside it. The steering head and the drawbar are mounted to the body and bolted mudguards. Then you can screw on the back and the two bars. All screw and bolt must be easily accessible.

build carts - for young and old

Tighten machine screws

If too much paint has run into a hole is drilled this out before installation. The machine screws must be tightened after the first use, as the washers still push into the wood at the beginning. The instructions for colored figures of the car found in the surface tip.

Tip surface

build carts - for young and oldbuild carts - for young and old

First, the wagon is disassembled into individual modules. Then spackles the visible screw holes with polyester filler (car spatula) to and grinds the dry putty carefully. For a clean filled surface always two filler passages are actually necessary, but this is due to the very fast drying time of leveling compound no problem. Then, when everything is slurred, you have to worry about which part is to get what hue. Then, the items can be painted with a brush. After the first coating a so-called intermediate sanding with sandpaper (grain P240) must be performed, the second ink application occurs. As color is opaque acrylic or synthetic resin paints are suitable, but also the car paint from a can or opaque glazes on a biological basis. In order to apply graphics later, it manufactures on simple templates from cardboard and sprayed the spaces with the spray from. With a permanent marker, the transitions are then provided with more contrast.

build carts - for young and oldbuild carts - for young and old

building plan

build carts - for young and old

Courtesy of Festool

Photo credit

All photos: © Festool

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