Making the wheel.
Cut 1 standard fence paling (150x19x1800) into six pieces 300mm long.
Lay two pieces side by side, then glue (with sturdi bond or similar exterior glue) another two
pieces on top of the first two, running at right angles to the ones on the bottom.
Then glue another layer on top of the first two layers, again at right angles to the
layer below. Place a weight on top and leave for the glue to dry. (24 hrs or longer).
When the glue is dry, draw a circle with a 130mm radius (see diagram) and cut with a jigsaw.
Drill a 25mm hole (or slightly larger than the dowel axle) through the middle of the wheel.
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Cutting the pieces.
Refer to the diagram for cutting sizes. The grid lines in the diagram are 100mm apart.
Cut the 2 support rail and handle pieces (1180mm long x 50mm wide x 40mm thick)
out 100x40 pine decking. Shape the ends for the axle and handle (optional) as
shown in the diagram.
Cut the two legs out of 100x40 pine decking and cut to the shape as shown in the
diagram with a jigsaw.
All the tray pieces (tray base, side panels and end panels) are cut from standard
150x19x1800 fence palings.
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Fitting the tray base.
Place the two handles on flat ground so that the axle ends are 60mm apart (or slightly more than
the thickness of the wheel) and the handle ends are 400mm apart.
Lay the tray base (3 boards 150x19x400) on the two handles in the position as shown in the accompanied diagram
and fix with 50mm galvanized flathead nails.
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Fitting 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 8g x 50mm csk stainless steel screws. Drill the holes first with a 2.5mm drill bit.
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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Fitting the wheel and legs.
Turn the barrow upside down.
Cut a piece of dowel 200mm long (the axle) and put it through the hole of the wheel.
Place the wheel and axle on top of the two support rails so that the wheel is central
and straight.
Fix the wheel in place by securing the axle with metal pipe saddles screwed to the support rails.
Screw the legs to both the handles and the tray end panel as shown in the accompanied diagram.
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The finished wheelbarrow.
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