QUICK-BUILD PLAN SETS FOR TABLE SAWS al a er Tee Mm Racy — aa " 20 easy to buil full-sizey Wood Toy Cars and Trucl QUICK-BUILD PLAN SETS FOR TABLE SAWS ‘Toymaker Press is dedicated to providing you with the in’ plan sets you need to develop your skills as a toymaker. ‘your comments and any suggestions about this collection Email: johnlewman @toymakerpress.com L iene (CARS AND TRUCKS cuca STU oe Fist Rus3 ux th love ©2010 John W. Lewman -= Allrights reserved Printed in the China First edition Due to different conditions, tools, and individual skills, Toymaker Press, Ine. assumes no responsibility for any damages. injuries suffered, or losses incurred as. result of following the information published in this book. Before boginning any project review instructions carefully. If any doubts or questions remain consult local experts or authorities. Always read and observe all of the safety precautions provided by manufacturers of any fools, equipment or supplies. Follow all accepted safely procedures. Toymaker Press, Inc. ‘Shawnee, KS 66216 ww toymakerpress.com isan 978-4-4507-0045-0 | lll | il, ? "781490700650 ©2010 doh W LevmanWood Toy Cars and Trucks QUICK-BUILD PLAN SETS FOR TABLE SAWS ‘TABLE OF CONTENTS (Getty SAY een Motto Bus Pian Sets SnowPlowPianSet & Salvage Trailer Plan Sete 83 Geo GanPlin Set cess ee ae ($2010 Jann W, Lawman, i ppiveveeGetting Started @a Ga Ge Ba BB cea Hand crafted wood toys are a pleasure to make for fun or for profit. You can easily get started using simple tools and readily available materials. miter box and-sow ‘10° ae it than el S 716 at be (Gel started wits just a hand saw and miter box, plas a hand dll with 28" and 7/16" cil bis and easy to tnd supplies. Setting Up a Basic Toymaker Shop All you need to get started are basic hand tools. Be: with a hand saw and miter box, plus a hand dill with 378° ‘and 7/46" dill bits. Standard lumber yard wood, wood dowels, woodworker’s adhesive (glue), sandpaper and packot standard lumber paint complete the list aahesive Sanepaper yard wood Ifyou want to go inte production and build « large 5 : : number of toys for profi, a smalltable sav, band sawor Gathering Materials and Supplies scroll saw works great. Add to that a small dill press or electric hand dri and you have allthe power tools you Vis your local home improvement center and to need to get your business started. purchase everything you need to get into production. You'll need glue, sendpaper and wood for starters, The ‘lou dan pak up baals pisdiclon poweephep WA: body and chassis of each toy are best constructed from alow cost table saw and a low cost drill press. Used the lighter woods like spruce, white pine and poplar. ‘equipment offen works just as well as new. We often purchase our tools off the internet. There are a lot of Wheels, hubcaps and axles are made from standard hardwood dowels. The edges of the wheels are rounded reat sites that offer competitive pricin, = Se by hand using 100 grit sandpaper, sz Each of the toys is painted with non-toxic water based 2s acrylic latex enamels, Hardware stores and other paint & = ¢¥ he suppliers usually have a solection of bright acryic latex enamel colors in half-pint to quait size containers, The smallest containers of paint will coat several toys. tow cost bbw oot fae saw ‘rit press NON-TOXIC Water based acryle latex Ifyour workspace is limited you can arrange a temporary ‘setup to make several tays on the kitchen table. Itis a good idea to keep a vacuum cleaner handy to pick up the sawdust as you wark, The cuts are small and do not create a lot of waste material and vacuuming savdust as you build insures a clean, professionally built toy. ©2010 ohn W Levman -aa- 2 paint rush from Home DepotTransferring en Plan Onto the Wood ‘The tay plans inthis book are compl with full size drawings for every part Each of the parts is made from dimensional lumber, The lumber thickness called out for each partis available at lumber suppliers or can be easily cut with your saw, Lumber is commonly available in 1/2", 3/47 and 1-1/2" thicknesses. All the toys in the book are designed, around these dimensions. standard 10’ measuring tape works great for transferring the dimensions from the toy plan onto the Wood stock. A standard 12° ruler also works well. lead pencil can be used to prevent staining and denting the wood when marking dimensions. Cutting Parts to Size Each partis shaped with straight cuts only, This method creates the unique blocky style of the toys. It also makes. it easy to produce several toys quickly. Fallow ali manufacturer's safety rules that are packaged \with the saw, drill and all tools, Please review the Operater’s Manual often as a reminder to practice safe and responsible crafting, Gluing Parts Into Assemblies Athin layer of woodworker's glue is applied to each part. ‘The gluing surface of each part to be glued together must be covered evenly with glue, Press the parts together tightly. Set the assembly aside until he glue has dried, Sanding Parts to Shape ‘The edges of each toy are rounded fora finished Jook and for safety. It also prevents splintering while minimizing the damage if the toy is thrown or dropped. Wheel edges are also best when rounded. Edges are rounded by folding a sheet of 100 grit sandpaper into ‘a small pad and sanding each edge vigorously for the desired roundness. If beveled edges are preferred wrap the sandpaper around a small flat piece of wood. Applying Final Touches to the Toy After the parts are glued together and the glue is dry lightly apply one coat of paint to the assembly as primer. Prime the wheel and hubcap assemblies separately from the toy body. Do nat paint the axles. Keep paint out of the axle holes in the toy be and out of the holes in the wheels that receive the axles by inserting a scrap of axle dowel in each hole. Remove the scrap dowels after painting the wheels. The first coat of paint will appear a litle rough or spotty because the moisture from the paint causes the grain of the wood to swell Make sure the paintis thoroughly dry then sand the first coat with 200 grit sandpaper until the partis smooth. Do not sand the painted toy down to the bare wood. Apply atleast 2 more coats of paint for a pro- fessional finish, Sand each coat except the final coat Bringing It All Together Place a drop of glue into a whee! hole and insert the unpainted axle firmly into the hole. Insert the axle and Wheel assemblies into the axle holes in the toy body. Place a drop of glue into the opposite wheel and then press the whee! frmiy onto the ale. Repeat for each axle hole in the toy body. The toy is now finished and ready for play. With a little planning you can make several wood toy cars and trucks in a few hours. And by using common lumber to keep your costs low you can build the entire set and stay within your budget. So let’s get started! ©2010 Jann W, Lawman,COUPE PLAN SET ©2010 John WW Lewman pageCoupe Flan Set COUPE PARTS LIST T.CHASSIS = MAKE1 TAX IANE KA PINE 2. TOP MAKE 1 34° 1-3/8" X2-9/16" PINE S.WHEEL = MAKE4 42K 1-14 DIA, = DOWEL, 4 AXLE MAKE 2 2-14" X 3/8" DIA. = DOWEL 5.HUBCAP = MAKE 4/8" K 1" DIA. DOWEL NOTE: All body parts can be sawn from 1x4 and 2x4 lumber. Wheels, axlos and hubcaps are sawn fram standard diameter dowels. See parts list for sizes. 5. HUBCAP 1/8" X 1" DIAMETER (Make 4) 3. WHEEL 1/2" X 1-1/4" DIAMETER (Make 4) 4, AXLE 2-114" X 318° DIAMETER (Make 2) 38" 244 4. CHASSIS 1-1/2" X 1-1/2" X 4” (Make 1) iE ©2010 ohn W Levman pages1 Round off the edges of the chassis and the top ‘edges of tho top slightly as shown above prior to applying the woodworker's glue to the underside of the top. A piece of 100 grit sandpaper wrapped around a ‘small block works well for creating smooth and straight rounded edges. 4. Painting the coupe is a lotof fun. Ittooks reat both painted and tunpainted but color adds a lot of punch. The ‘coupe can be painted ‘asolid color with the wheels and arles a contrasting solid color. ‘Or the coupe can be painted with multiple colors to create some great looks. Coupe Pian Set 2, Press the top down onto the chassis and slide it around fo spread the glue evenly. Once you feel the glue has a good grip press down on the top to seat it against the chassis. The top is slightly narrower than the chassis ‘50 be careful to align the sides of the top side to side in the center of the chassis, 3. Place glue on the hubcaps and ‘center the hubcaps on the wheels, ‘Slide the hubeaps around and press downto achieve a tight fit. Do not attach wheels and axles to the chassis: until after the painting steps are completed. 5, The coupe is first painted a solid color. Apply at least 3 coats, sanding between with 200 grit paper. Once dry the contrasting ealar areas are ‘masked off using painter's trim ‘masking tape for a clean edge after tape is pulled off, Water based enamel is used for all of the colors. The hubcaps are painted with a small artist's brush without masking 7018 We LewMASports Car Plan Set ©2010 ohn WLevman pagesSports « = a &‘Spots Car Plan Sat SPORTS CAR PARTS LIST T.CHASSIS «MAKE 1 TA KIANE KA PINE 2. TOP MAKE 1 3/4" K 1-3/8" X2-9/16" PINE S.WHEEL = MAKE4 42K 1-14 DIA, = DOWEL, 4 AXLE MAKE 2 2-14" X 3/8" DIA. = DOWEL 5.HUBCAP = MAKE 4/8" K 1" DIA. DOWEL NOTE: All body parts can be sawn from 1x4 and 2x4 lumber. Wheels, axlos and hubcaps are sawn fram standard diameter dowels. See parts list for sizes. 4. CHASSIS 1-1/2" X 1-1/2" X 4" (Make 1) 5. HUBCAP . . 1/0" X 1" DIAMETER (Make 4) 2. TOP 3/4” X 1-3/8" X 2-9/16" (Make 1) © st ae r IL = 3. WHEEL 1/2" X 1-1/4" DIAMETER (Make 4) 4, AXLE 2-114" X 318° DIAMETER (Make 2) 38" 24/4" 4 ©2010 ohn W Levman pegeTTs 4. Round off the edges of the chassis and the top edges Cf the top stightly as shown above prior to applying the Woodworker's glue to the underside of the top. A piece of 1100 grit sandpaper wrapped around a small block works well for creating smooth and straight rounded edges. 3, Place glue on the hubcaps and center the hubcaps an the wheels. Slide the hubeaps around and press down to achiove a tight fit. nt Y 4, The sports car looks sroat painted and Lunpaiited. Color adds a {ot of punch. Paint it a sofid color with the wheels a contrasting color. Orit can be painted with multiple colors to create a variety of performance car combos. pages Sparta Car Pian Set 2. Press the top down onto the chassis and slide it ‘around to spread the glue evenly. Once you fee! the glue has a good grip press down on the top to seat it against the chassis. The top is sightly narrower than the chassis ‘so be careful to align the sides of the top side to side in the center of the chassis. Do not attach wheels to axles until after the painting steps are completed. 5. First paint the sports car solid color, Apply 3 coats, sanding between with 200 grit paper. Gontrasting colors are masked off with painter's trim masking tape for a clean edge. Water based enamel is used {or all colors. The hubcaps are painted with an attist’s brush, F018 Lew‘Wagon Pian Set WAGON PARTS LIST 4.CHASSIS MAKE 1 NZ K AKA PINE 2.T0P MAKE 1 BX 138"X3 PINE S.WHEEL = MAKE 4 RK 1-14 DIA, DOWEL 4 AXLE MAKE 2 24/4" X 3/8" DIA, = DOWEL S.HUBCAP = MAKE 4 Ve K 1 DIA, DOWEL NOTE: All body parts can be sawn from 1x6 and 2x4 lumber. Wheels, axles and hubcaps are sawn from standard diameter dowels. See paits lst for sizes. 1, CHASSIS 1-1/2" X 1-1/2" X 4" (Make 1) 5.HUBCAP | 4/6" X 1" DIAMETER (Make 4) aa TOP 3/4” X 1-3/8" X 3" (Make 1) 5 wae | ve k 4" af. sf } 3, WHEEL 1/2" X 1-1/4" DIAMETER (Make 4) 4. AXLE 2-114" X 3/8” DIAMETER (Make 2) e = [es 2010 doh W Levman page 1 javepuan, sauluul1. Round off the edges of the chassis and the top edges of the top slightly as shown above prior to: ‘applying the woodworker's glue to the underside of the top. A piece of 100 grit sandpaper wrapped around a small lock works well fr ereating smooth and straight rounded edges. 3. Place glue on the hubcaps. and center the hubcaps on the wheels. Slide the hubeaps around and press dawn to achieve a light fil, Do not attach wheels to axles until after the painting steps are completed. 4. The wagon looks great painted and unpaintad. Color adds a lot of punch. Paint ita solid color with the wheels a contrasting color, Orit can be painted with multiple colors to ‘create some striking great looks. age 12 Wager Pian Set around to spread the glue evenly. Once you fee! the glue has a good grip press down on the top to seat it against the chassis. The top is sightly narrower than the chassis so be careful to align the sides of the top side to sida in the center of the chassis. 5. First paint the wagon a sold color. Apply 3 coats, sanding between coats with 200 grit paper. Contrasting colers are masked off with painter's: ‘im masking tape for a clean edge. Water based enamel {is used for all colors. The hubeaps are painted with an artist's brush without masking. (62019 4onn W, Leman.wt ae 5, 5 D3"Pickup Plan Set PICKUP PARTS LIST T.CHASSIS MAKE 1 12K ANZ KA" PINE 2.TOP MAKE 1 Bid" X 4-3/8" X 1-5/8" PINE 3,WHEEL = MAKE 4 12K 1-8" DIA, = DOWEL NOTE: Al body parts can be sawn 4 AXLE MAKE 2 2-144" 3/8" DIA, «= DOWEL. ‘rom 4x4 and 2x4 lumber, Wheels, atles and hubeaps are sawn from 5,HUBCAP = MAKE 4 18" K 1" DIA, BOWEL standard diameter dowels, See parte list for sizes. G.FENDER = MAKE2 12 Ke X14" PINE 4. CHASSIS 1-4/2" X 1-1/2" X 4” (Make 1) 5, HUBCAP 2.70P 118" X 1" DIAMETER (Make 4) SER Bi X 1-3/8" X 1-516" WRK K ts ‘Quake (Make 2) | on LA jet; a i 3. WHEEL 1/2” X 1-1/4" DIAMETER (Make 4) 4. AXLE 2-114" X 3/8" DIAMETER (Make 2) 3/8" 21/4" iE @2010 ohn W Levan page 15 ae1. Round off the edges of the chassis and the top edges of the top slightly as shown below priar to applying the Woodworker's glue to the underside of the top. A plece of 100 git sandpaper wrapped around a small block works ‘well for creating smooth and straight rounded edges. 2. Press the top down anto the chassis and side it ‘around to spread the glue evenly, Once you feel the glue thas a good grip press down en the top to seat it against the chassis. The top is slightly narrower than the chassis so be careful to align the sides of the top side to side in the conter of the chassis, fener 3. Apply glue to fenders and press each into place on the chassis siding each fender slightly to spread the glue evenly, See side view page 14 for exact fender Positioning. Once you fea! the glue has a good grip press down firmly to seat each part on the chassis. Add the top to the chassis repeating the sane steps. 4, Place glue on the hubcaps and center the hubcaps on the wheels. Side the hubcap around and press down to achieve a tight fi Do not fit wheels and axles to the chassis until after the painting steps are completed. page 16 Pickup Plan Set 5. Painting the pickup is a lot of fun. tt looks great both painted and unpainted but color adds a lat of punch. The pickup can be painted a solid color with the wheels and axles a contrasting solid color, Or the pickup can be painted with muttipfe colors to create some great looks. 6. The pickup shown is first totally painted a solid color. Apply at least 3 coats, sanding between with 200 grit paper. Once dry the contrasting color areas are masked off using painter's trim masking tape for a clean edge after the tape is pulled off, Water based enamel is used forall of the colors, The hubcaps are painted with a ‘small artist's brush without masking. ($2019 4onn W, Lew,Minivan Plan SetMinivan Plan Set pparts fst for sizes MINIVAN PARTS LIST A.GHASSIS MAKE1 | 1412"X1472"K4" 2,TOP MAKE1 3/4" 1-9/8" x 3-49/16" S.WHEEL © MAKE4 1/2" 1-1/4 DIA, NOTE: Allbody pats can be sawn AXLE = MAKE2 2-1/4" 0" DIA, eee toes ere S.HUBCAP MAKE4 1/8" 1" DIA. re Seely diets See 6.FENDER MAKES 12" K 12K 1-104" PINE PINE DOWEL DOWEL DOWEL PINE, 4. CHASSIS 1-1/2" X 1-1/2" X 4" (Make 1) 5, HUBCAP 118" X 1" DIAMETER (Make 4) 2.T0P 3/6" X 1-318" X 3-13/16° 01) 15116" Jee koe aaah" 1 3. WHEEL 1/2" X 1-1/4" DIAMETER 6. FENDER (Make 4) 4/2? X 1/2" X 4-1/4" ‘Mako 4) 4, AXLE 2-11" X 3/6 DIAMETER (Make 2) [be 146" |3e | aaa" al ©2010 ohn W Levman page 19Viel 1. Round off the edges of the chassis and the top edges of the top slightly as shown above prior to applying the woodworker's glue to the underside of the top. Apiece of 100 grit sandpaper wrapped around a ‘small block works well for ereating smooth and straight rounded edges. ee 5. The minivan looks great painted and unpainted. Color adds a lot of punch. Paint It sold color with the wheels a contrasting color. Or paint the minivan with muttiple colors to create your own flower child ride. ‘Minivan Pian Get fender 2. Press the top down onto the chassis and side it ‘around to spread the glue evenly. Once you fee! the glue has a good grip press down on the top to seat it against the chassis. The top is slighty narrower than the chassis so be careful to align the sides of the top side to side in the center of the chassis, 2. Apply glue to fenders and press each fender into place on the chassis sfiding each fender slightly to spread the glue evenly. See side view on page 18 for fender positioning. 4, Place glue on the hubcaps and center the hubcaps on the wheels. Slide the hubeaps around and press. down to achieve a tight fit, Do not attach wheels to axles until after the painting steps are completed, 6. First paint the minivan a solid color. Apply 3 coats, sanding between with 200 ‘rit paper. Contrasting colors ‘are masked off with painter's tim masking tape for a clean edge. Water based enamel is used for all colors. The hubcaps are painted with an artist's brush, ($2019 4onn W, Lew,