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Toy Pickup Truck
This project appeared in our December 27th, 2002 Newsletter.

I know it seems a little late for toys but just because Christmas is over doesn't mean that there aren't some little kids out there with birthdays. This would make a great gift for that special child that likes real toys, if you know what I mean. Nothing nicer than a hand made toy.

Toy Pickup Truck Here's what you'll need:

  • 1 1/2" dia. X 12" grooved wheels.
  • 3/4" X 3" X 12" Maple or your choice
  • 1/4" X 3" X 8" Maple or your choice
  • 1/4" X 1 1/2" X 12" Poplar or your choice.
  • 3/4" X 1 1/2" X 16" Walnut or your choice.
  • 4 Axels for your wheels. You can get these at Rockler or make your own. We'll show you below how to make your own.
  • 1/2" X 1" X 8" Oak or your choice.

Here is the pattern for this project, PATTERN

The pattern is color coded to make it a little easier to see what's going on. The pattern for the running boards and fenders are for reference. You'll use the pickup body to actually make the outline for these.

Cut the bottom for the body 2 1/2" X 7 3/4" X 1/4".
Cut three 3/4" thick pieces for the cab, 2 1/2" X 4 1/2", 2 1/2" X 4 1/2" and 2 1/2" X 2 1/4 '.
Glue the three pieces onto the 1/4" body. Very carefully align the sides and the back of the cab.
While this is drying cut two 1/4" pieces 1 1/8" X 3 1/2" and two pieces 1 1/8" by 1 7/8". These will be the pickup box.
Glue the box together being careful to align all the corners and keep the top flat.

Pickup Box

Trace the pattern for the side of the truck onto the glued pieces and cut them out with a band saw.

This next step is a little more difficult but trace the top of the truck onto the wood. I used a square to align the front of the pattern with the front of the body since it tapers back a little.
Align Front

Cut out both sides of the body and sand all the edges round.
Glue and clamp the box onto the truck body.
Box to Body

Glue two 3/4" pieces of Walnut 1 1/2" wide and 8" long together. Make up two of these for the fenders/running boards.
Place the body of the pickup 1/2" in from the edge of the Walnut piece with the non-seam side up. Draw the body shape onto the Walnut and cut out with a band saw.
Trace the pattern for the side of the fender/running board onto the piece. Cut out the profile using a band saw. Use the piece of wood removed from the previous cutting to support the narrow side of the part.
Repeat this process for the other side. Be very careful cutting the body shape because this has to fit perfectly later on.
Round the top edges using a 1/4" router bit.
To make the wheels sit inside the fenders we ground them out a little using a drum sanding bit in our drill press. We relieved them about 1/8".
Cut two pieces of 1/4" X 1/2" X 2 1/8" for the axels to fit into.
Glue the back piece 3/4" from the back of the truck.
Align the front piece 1" back from the front and mark the angles of the truck nose onto it. Cut the piece to the shape and glue in place.

Axel Frames

Using a 1 5/8" Forstner bit countersink pockets for the wheels. Using the fenders as a guide draw a line inside the fenders to show you where the countersink needs to go. Make them approximately 1/8" deep.
Countersink Wheel Sockets

Align the fenders onto the body and mark the centers of the wheels. Allow room for them to turn. Drill 1/4" holes for the axels to go into.
If you don't have axels for your wheels here is a simple way to make them. Drill a 1/4" hole 3/4 way through a 3/8" hole plug. Cut a 1/4" dowel 1" long and glue it into the plug.

Glue the wheels onto the truck making sure that they turn freely.
Now is a good time to stain your project if you like.
Glue the fenders/running boards onto the truck. Clamp them good and make sure again that the wheels turn freely.
Clamp Fenders/Running Boards

While they are drying make the bumpers out of 1/2" Oak. Cut two strips 2/8" X 4". Trace the bumper pattern onto the pieces and cut them out using a scroll saw.
Round the edges with an 1/8" router bit.

Glue the bumpers on and you are done except for any finish you want to put on. I used rubber bands to hold the bumpers on while they dried because I didn't have any clamps that big.

One word of caution if you are giving this to a young child as a gift. The wheels and or axels could come off making a possible choking hazard. I would suggest using good judgment in giving this gift.

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