{"id":1221,"date":"2016-08-04T05:44:21","date_gmt":"2016-08-04T12:44:21","guid":{"rendered":"http:\/\/www.giassa.net\/?page_id=1221"},"modified":"2025-08-24T08:03:52","modified_gmt":"2025-08-24T15:03:52","slug":"thomas-the-tank-engine-styled-wagon","status":"publish","type":"page","link":"https:\/\/www.giassa.net\/?page_id=1221","title":{"rendered":"“Thomas the Tank Engine” styled wagon"},"content":{"rendered":"

My little guy, 18 months at the time I started this, was a big fan of Thomas the Tank Engine. With his plastic store-bought wagon broken due to a damaged wheel, I figured we could make something far more entertaining out of some SPF planks.<\/p>\n

\"IMG_20160719_065655\"<\/p>\n

First, a 2′ x 5′ frame (outer dimensions) using 2×4’s, waterproof wood glue, and pocket holes via a Kreg jig. I initially had planned to add a steering mechanism via a steering wheel, pair of shafts, universal joint, and a rudimentary Scotch yoke (below). A metal 1\/4″ threaded shaft would join the front castors I used for wheels, with a metal loop bolted onto it, and the far end of the steering mechanism connected to a flywheel. Given my kid and his friends asking for train rides while the project was barely, built, I figured there was no need for it.<\/p>\n

\"Scotch-Yoke-in-color\"<\/p>\n

Next, some paint, putting down some 1×6 planks for a floor,\u00a0 and affixing some support posts with heavy brackets and pocket holes.<\/p>\n

\"IMG_20160723_155819\"<\/p>\n

Now, time to add some side panels…<\/p>\n

\"IMG_20160724_143306\"<\/p>\n

Bench seats, doors…<\/p>\n

\"IMG_20160724_174042\"<\/p>\n

Now for the biggest frustration in the whole project, the cosmetic “tube” at the front of the train. I ended up running some 1×6 planks through the table saw at 22.5 degrees, and gluing the sections together with a web ratchet. Took a few tries to get everything aligned properly. The front cover panel was some 1×6 planks glued together along the edges, and cut into an octagon using a miter saw.<\/p>\n

\"IMG_20160730_120437\"<\/p>\n

Everything painted, assembled, and ready to go. I bolted on a heavy 2×4 to act as a “lock” for the doors, so they couldn’t open while the “train” is in motion. I left a small gap near the front, right above the black “tube” portion. I’ll later add either a piece of plexi glass or a headlight there.<\/p>\n

\"IMG_20160731_143459\"<\/p>\n

Finally, (not shown) I added some simple electronics to implement a pull-down trapeze-style handle to make a loud horn sound effect. Just a pre-built audio evaluation board which I connected to a tiny 8R speaker, and a large snap-action switch which connects to a piece of paracord to activate the audio functionality. All the interconnections were done with 0.1″ crimped cables using kits purchased from Hansen Hobbies<\/a>. The Digikey bill-of-materials (BOM) for the electronics is included below.<\/p>\n