NOTE: All the pieces used in this project are cut from 1x2 and 1x6 boards (see materials list).

Making the wheel
Cut six pieces of 1x6 board 12" long. Lay two pieces side by side, then glue (with exterior type glue) another two pieces on top running at right angles to the first boards. Then glue another layer on top of the first two layers, again at right angles to the layer below. Place a weight on top or clamp together and leave for the glue to dry.

When the glue is dry, draw a circle with a 5" radius (see diagram) and cut with a jigsaw. Drill a 1" hole (or slightly larger than the axle) through the middle of the wheel.

Cutting the pieces
Refer to the diagram below for the cutting sizes and shapes.
All the pieces can be cut from 1x2 and 1x6 boards.
They are....
2 pieces of 1x2 stock 47" long for the support rail and handle pieces [A].
2 pieces of 1x2 stock 16" long for the legs [D].
2 pieces of 1x6 stock 18 1/8" long for the end tray panels [B].
2 pieces of 1x6 stock 20 5/8" long for the side tray panels [C].
3 pieces of 1x6 stock 16" long for the tray base [E].
Cut and shape as shown in the diagram below.

Making the tray base
Place the two handles on flat ground so that the axle ends are 3" apart (or slightly more than the thickness of the wheel) and the handle ends are 16" apart.

Lay the tray base (3 boards 1x6 x 16") on the two handles in the position as shown in the accompanied diagram and fix with 2" galvanized flathead nails.

Fixing the tray side panels
All the tray side and end panels have been cut at 15 degrees. Screw the end panels to the side panels with 2" csk stainless steel screws. Pre-drill the holes first. The side tray panels will sit on the tray base, but the end tray panels will sit against the tray base. See accompanied diagram.

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