Presenting Harry & Sal's Billy Cart
Tools you will need
- Carpenters square
- Marking pencil/scriber
- Rule/measuring tape
- Drills and Bits
- Wood chisel
Materials you will need
Several different combinations of timber would be acceptable provided the
components shown as A, B, C and D are sound, and are relatively free of
strength reducing imperfections such as large knots, splits, etc. You
may prefer to use Appearance grade timber.
Consult your TABMA Timber Merchant (or your local equivalent)
concerning availability of stock,
dressed-all-round (DAR) timbers, seasoned or unseasoned, at least of
structural quality. Some suppliers may be able to dress material to-order.
TIMBER SIZES TO ORDER
Note: Your TABMA Timber Merchant will provide sufficient timber from which the
handyman can cut the lengths required. Some suppliers may offer a cut-to-size
service for an additional charge, or you may need material cut so as to fit in
your cara boot or cabin.
- 75 x 50mm DAR
2 pieces 600 mm for parts A, B, (may need adjustment to suit axles/wheels
1 piece 1.2 m for Part D
1 piece 380 mm for Part C
- 200 x 25 mm DAR
4 pieces 595 mm for Parts E, F
- 75 x 25 mm DAR
2 pieces 380 mm for parts G, H
1 piece 90 mm for Part J
First select the axle plus wheel plus support brackets from your hardware
supplier. Typically, axles of 600 mm lengths are available and suitable.
At least two yupes of wheels could be available to fit on the axles.
- 2/600 mm x 12 mm axles and brackets
- 2/150 mm wheels to fit front axles
- 2/200 mm wheels to fit rear axles
- 4 split pins to fit axles
- 8/ washers to fit axles
- Screws/bolts supplied as kit with axle brackets OR, appropriate bolts to
fix brackets to parts, A,B.
- 1/115 mm (approx) x 9.5 mm hex. head bolt
- 29.5 mm nuts to fit bolts
- 4/9.5 mm 24/50 mm x 2.8 mm flat head nails
- 2/50 mm x 6 mm cup head bolt
- 2/6 mm washers
- 2/38 mm x 3.15 wood screws
- 2 metres rope
Step by step instructions
Cut these from the 75 x 50 mm DAR.
Note Dimension shown for C should be equal width of seat made up of two widths
of parts E.
Cut these from the 200 x 25 mm DAR timber.
Cut these from 75 x 25 mm DAR.
Note Dimension G should be equal to width of Part C.
Step 4: Assembling frame
Bolt pieces B and C to centre board "D" as shown. Use 50 mm x 6 mm cup heads
bolts, nuts and washers. Head of bolt must be on the top side of D. Ensure
that B and C are at right angles (square) with D. To make a stronger joint
use a standard PVA wood glue on these joints.
Step 5: Fitting wheel brackets
Fix axle brackets to Part A and B, using screws/bolts as appropriate. Heads of
bolts must be on the top side of Part D if used. Front wheel brackets must
be positioned to allow rope holes on the forward part of Part A and so located
that the axle position leaves pivot bolt and nuts accessible for
Step 6: Assembling steering
Attach pieces, Part A to Part D using the 115 mm x 9.5 mm hexagonal bolt with
washers and nusts as shown with locking nuts on top of Part D (first check
that hex head clears axle, you may need to sink int into bottom of Part A.
(Part J) Screw block for the steering lock Part J to the underside of Part D,
30 mm behind Part A, using the two 38 x 3.15 mm wood screws. Thread Rope
through holes in front edge of Part A and tie double knots on the underside
Step 7: Fitting seat
Nail the seat boards Parts E, on the cross braces, Parts C and B, such that the
boards cover top side of Part C, fitting flush with front edge and side (or
ends). Use four nails per board fixing firmly to Parts C and B. Nail sides
(Parts F) into the edges of seat boards and into the ends of Part C. Note the
cut-outs on side Part F are sized to fit closely over Part B. Use four nails
per side. Nail seat back, Part G between sides F. The position of the seat
back should be adjusted along the length of the side depending upon the
size of the drivers. Use two nails each side of seat brace, nailing through
side, Part F into ends of seat back, Part G.
Step 8: Assembling wheels
Slide larger diameter wheels on to rear axles, with metal bush to the inside, or
use washers as shown. Finally, insert split pins and bend open. Repeat
procedure for front wheels.
Step 9: Fitting footrest
With wheels fixed, position the driver on the seat then locate the footrest,
Part H onto the top of Part D. Use two nails to fit the footrest in position.
10: The final step
The final step is to round off all sharp corners with plane or sander and
finish all over with your selected paints.
Timber Talk with Harry & Sal
Disclaimer: While the Timber and Building Materials
Association (NSW) Limited (TABMA) and its members believe this publication
is an invaluable guide to this project, the Association cannot guarantee
that every statement is without flaw. Therefore, the Association and its
members hereby disclaim all liability for error or omissions of any kind,
whether they be negligent of otherwise, or for any loss, damage or other
consequence which may arise from any person relying on information stated in
This document was prepared with the assistance and co-operation of the
Timber Development Association NSW Ltd.
For further advice telephone the TDA Timber Industry Advisory Service on
(02) 360 3088.
Copyright Owner: Timber and Building Materials Association (NSW) Limited.