~ FAVORITE TOYS

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BAJABUGGYYoungsters will feel the

wind through their hairand the summer sun upontheir faces when driving thisbeach buggy over the dunes ofmake-believe. This fat-tired toyrequires just a few feet of 2X 4stock and about 21f, .hours tobuild. Can you think of aneasier child pleaser?

Shape the body and fenders1. Plane or resaw two 12"-long

pieces of pine or fir 2 X 4 stock tolYt6" thick. You also could usefive-quarter (5/4) stock andeliminate the planing. Glue andclamp the pieces together face toface for the car body (A).

2. Transfer the full-sized caroutline and axle-hole locations toa piece of paper. (We photo-copied the pattern; you also coulduse carbon paper.) Cut the patternoutline to shape. Apply spray-onadhesive to the back side of thepaper pattern, and stick thepattern to the pine block.

FENDER@

7/'6" hole_....3»o._~for axle

I3. Drill a pair of }';6" axle holes

through the body where marked.4. With a W' blade on your

band saw, cut the car body andwindow opening to shape.

5. Plane or resaw another 12"-long piece of 2 X 4 stock to 1Yt6"thick. Using. the same transferprocedure described in Step 2, layout and cut the two fenders (B)to shape.

6. Sand a radius on the frontand rear outside corners of the'fenders as shown in the Fenderdetail. (We marked the radii with

a quarter, and shaped the radiiwith a belt sander.)

7. Remove the paper pattern,and hand-sand the car body andfenders.

8. Drill a pair of 1'0" holes !I,"deep in the front of the car bodyto form the headlights. (We heldthe car body upright in a hand-screw clamp. and drilled the holeson the drill press.)

9. Glue and clamp the fendersto the car body where located onthe Full-Sized Pattern The. bottommiddle section of the fendersshould be flush with the bottomof the car body. Wipe off theexcess glue with a damp cloth.

SCut through hereto form window opening

~--------~~~--FULL-SIZED PATTERNS

Let's add the wheels1. Plane two 12" lengths of 2x4

stock to 1Y",". Laminate the twopieces together face to face.

2. Using a compass, mark fourZY.o"-diameter(J Y,(," radius) circleson the top face of the laminatedstock for the wheels (C).

3. Chuck a I" Forstner orpaddle bit into your drill press.Drill a lY.(."-deep hole at the cente •.or each marked wheel. Switch to abrad-point bit, and drill a %" holethrough the center of each wheel.

4. Using a bandsaw, cut (hefour wheels to shape, cutting justoutside the marked outline.

5. Fasten a wheel to a 5"-longpiece of %"-threaded rod whereshown on the drawing at far right.Chuck the assembly into yourdrill press. With 80-grit sandpaper,sand the wheels smooth (we useda sanding block). Sand a W'round-over along the outsideedges. With the drill press'stopped. check the sanded round-overs for uniformity. with a- .%"round-over bit as, shown in thephoto aboue right. Finish-sand withfiner grits of paper. Repeat theprocess for the. remaining wheels.

6. From W' dowel stock, cuttwo axles each 4%" long. Glue oneaxle, flush with inside edge of the1" hole, to each wheel, (See theExploded View drawing forreference.) Insert the axles throughthe car body, and glue on theother two wheels so the wheel-axle assemblies rotate easily.

Sand a radius onthe outside corners

of fenders.

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Apply the firrish and head forthe dunes

1. Apply two coats of clearfinish. (We found that an oilfinish tends to pick up too muchdirt over time. but. paint, lacquer,or polyurethane work well.)Now, watch a deservingyoungster's imagination run wild.

When sanding th.e band-sawedwheels to shape on the drill press,check round-overs with a ¥O"round-over bit for uniformrt- ..

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7/'6" holesV4" deep

--,, __ 3/8" dowel is flush with EXPLODEDbottom of I" hole VIEW

\I~~~ __ I" hole 1'/'6" deep with a3/8" hole centered inside

TOP VIEWFENDERDETAIL

Use a quarterto mark

fender radius

Bill of MaterialsPart _.:.F.;c.i"__is:..h.:...;ed-,,-S:...;.iz=-eO--_Mat. Qty

T w L

iI

t I! 1! Ii ~

A body 2~" 3W 5~" LP 1

B fenders 1X.. 1J{" 5~" P 2

C wheels 2~" 2~" diam. LP 4

Material Key: LP-Iaminated pine; P-pineSupplies: W dowel stock, spray adhesive,finish, wax, 0000 steel wool, lixS"-longthreaded rod with two W nuts and flat washersfor sanding arbor.