A Traditional Small Trolley or Cart.

This small cart was designed to take 2 small passengers or some cargo. The construction was mainly from wood with some metal parts to make the handle.

Many of the sheet timber parts were designed to overlap when assembled, so that most of the sizes were non-critical.





















The cart was designed to be made from plywood, or any other sheet timber.

My neighbour was discarding an old wardrobe which he let me have. This provided more than enough wood. It wasn't hardwood but good enough.









The sides and base were marked out as indicated by the plans and then cut out. The edges were sanded to get the final shape.









The sides were assembled using some of the reclaimed wardrobe fixings.

Self-tapping wardrobe fitting









The rear axle was cut from a block of hardwood.

The cut-out on the underside was simply to allow the axle to be held without the need to drill the 10mm hole all the way through which would be difficult and require a long drill.

The holes were drilled by hand as parallel to the axle housing as possible. In reality the holes had to be opened out to 11mm to get the axle to slide all the way through.









The photograph below shows the axle end detail. The washers and 10mm nuts were standard parts. The tube was a piece of 12mm diameter pipe which was a running fit in the hub of the wheel. This was drilled out to 10mm to fit on the axle rod and was turned to a length 0.5mm longer than the width of the wheel hub.

The completed rear axle.


The nuts on the inside were used to give the outside wheel nuts something to clamp against rather than the wooden beam taking all the force.

If preferred the wheels could just run on the threaded rod, but the pipe bearing would give a smoother running fit.









This image shows the front axle ready to take the wheels. A piece of wood of the full thickness was not available so two blocks were bolted together as shown. The bolts were needed anyway to hold the metal steering arms.

The steel box sections were difficult to keep central on the 8mm threaded rod and so some wooden bungs were inserted into the lower end. These were drilled centrally 8mm to give support.













The steering pivot was a piece of 10mm threaded rod running in a 12mm piece of pipe. As the wood for the base of the cart was only soft pine, a block was screwed to the inside to give extra support.

Steering support block









The sides of the cart were secured to the base using some screws up through the bottom. This photo also shows the steering axle installed, secured with two Nyloc nuts.









The handle for the cart was a piece of 16mm square box section. It was drilled through both ends with an 8mm drill. The top end was fitted with a piece of 8mm threaded rod which had some fuel hose fitted on it to form a handle.

The Handle









The lower end of the handle had a short length of 8mm threaded rod held in place with two nuts plus two washers. The length of this rod was cut to be just less than the distance between the two pieces of threaded rod, which were holding the steering arms in place.

General view of steering and handle assembly

Handle Pivot









At this point the trolley was ready for a quick road test. Initially the steering was a little tight, but it soon loosened up after a few turns.

The other concern was the steering arms. They were strong enough for pulling and steering, but they could twist quite easily. This twisting was reduced by slightly tightening the threaded rod nuts, but time would tell if this would be a problem or not.

The steering arms could be made shorter if needed, but it was quite nice that the arm could be leaned back as shown, when the trolley was parked.









The rear axle was re-enforced by adding a couple of triangular wood off-cuts.









Two seats were added to the cart supported by batons on each side. The seats were screwed in place but could be made removable.