The Conestoga Wagon build

Kevin · Oct 10, 2012

Kenbo said:
I got out to the shop today and put in 2 hours.
Sadly enough, all the work I did on the weekend was nothing more than designer fire wood and kindling. There were several problems that made them that way. The main problem was that the wheel would not fit in the main area of the heptagon without encroaching into the waste areas. I considered cutting the pieces smaller to try and shrink the heptagon and avoid the waste areas but I decided that this was more trouble than it was worth. So, I cut all new wagon sections.

I know it doesn't seem like much, but remember that I had to cut the stock from 8/4 rough sawn, then thickness plane down to the 3/4" that I needed. The resaw and stock prep took some time.
Here's the difference in the old pieces and the new.

Part of my problem with the wheels, is that I don't have a compass large enough to draw the 13 1/2" diameter so I was kinda Mickey Mousing it. I got tired of that and headed to Lee Valley today. I've always been a fan of Veritas products and the fact that they are Canadian is just a bonus. I don't think that I've ever been disappointed with a Veritas purchase.
I decided that I would pick up a set of Veritas beam compass ends. They seem a little expensive, but I'm worth it.

They attach firmly onto the beam and once they are set, they do not move. There is absolutely no play in these puppies at all. They are extremely sturdy feeling and you never feel like you are going to break them.

They even come with their own rigid carrying case to keep them safe. I've wanted a set of these for years. I don't know why I didn't do it earlier.

I'm also proud to say I have bought plenty of tools/equipment/items from Canada and I can't remember ever being dissatisfied. And I love Veritas products. I used one of their angle jigs while teaching my muscle memory for eventually freehanding the larger plane knives and chisels for Scary Sharp sharpening and you just can't go wrong with Veritas products for sure.

woodtickgreg · Oct 10, 2012

Your so right Ken, you are worth it! :drinks:

Kenbo · Oct 15, 2012

I made it out to the shop today and cut the rabbets for the half lap joints of the wheels. I then dry fit them together, and marked the waste areas. After all the waste areas were marked, I sanded them off and glued the wheel sections together. I know that this is not the way it is supposed to be done, but I dont like the plans way of sort of telling us in a round about way how to do it. In other words, the plans tell you nothing!!
Mrs Kenbo came out in case I needed an extra hand for the glue up and I did. Of course, she had to photobomb my picture so I think that means I can post it.
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Brink · Oct 15, 2012

Nice Ken, you're doing a wheel fine job, if I say so in a round about way. I spoke to some fiends about this build, and it seems you just keep rolling through it.

I do like it.

Kevin · Oct 15, 2012

Keep on chooglin Ken. Looking good. Thanks for the pretty smile too. :sun_smiley:

Brink said:
Nice Ken, you're doing a wheel fine job, if I say so in a round about way. I spoke to some fiends about this build, and it seems you just keep rolling through it.

I do like it.

I know how you came about your user name now, because I'm on the brink of laughter. Not quite into the laughter territory mind you, but on the brink. :biggrin:

Mike1950 · Oct 15, 2012

Not to stray from this excellent thread but a little not about the compass. I bought a 75 yr old set of trammel points on ebay- $15.00 wonderfully made and I have no clue as to how I got along with out them. I also just bought for about $5 an micro adjustable set on a round steel rod. Keep your eyes open and these for very few dollars can make circles so much easier!!!

Ken as always your brake assembly is incredible in it's detail....................

Kenbo · Oct 16, 2012

Another 2 hours in the shop today after work. The wheels seem to be coming together this time.
I started off the day by unclamping my "wheels" that I glued up yesterday and traced the inside heptagon onto a scrap piece of 1/2" ply. I then cut this heptagon out, using my scroll saw, and sanded up to the lines to get the size just right.
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Now it was time to find the center of the heptagon. (I just like saying that word) Heptagon. :sarcastic:

The center is found by measuring and marking the center point on each flat edge, and drawing a line from that mark to the opposite sides point. The intersecting lines in the middle mark the center.
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I then placed the heptagon (there's that word again) into the middle of my wheel glue up and used my beam compass (did I mention that I love my beam compass?) to mark the inner and outer diameter of the wheels. The plywood center's only purpose here is to give me a reference point for the compass.
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I then headed over to the scroll saw (I'm kinda new at scrolling so I wanted to use it as much as i could to get some practice) and cut the inner diameter just proud of the lines. The outer diameter was cut on the band saw just proud of the lines.
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Then, over to the disc sander to sand up to the lines of the wheels.
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You can see my half lap joint here in the wheels.
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It was now time to sand the inner diameter of the wheels. I used the oscillating belt sander. (I'm a little disappointed that I don't get to say heptagon anymore)
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I then needed to mark and drill for the 1/4" dowel pins that will strengthen the half lap joints. I marked each hole and drilled it accordingly. Heptagon. :yipee:

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And here, we have both rear wheels cut, and drilled. I tried some dowels that I had in the shop, and I didn't like the way they fit. I'm thinking on making some 1/4" walnut dowels in my dowel cutting jig to give the wheel a little contrast. Hopefully, that will be tomorrow.
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Heptagon :good2:

woodtickgreg · Oct 16, 2012

HEPTAGON! There I said it :mocking:

Nice work, Maybe if you practice a lot on the scroll saw you could do portraits or something. :mocking:

Still enjoying your build! :good:

Kenbo · Oct 18, 2012

Spent another 1 1/2 hours of sanity time after work today in the shop. I got a little more done, but not much. I started off by making the dowels that I needed to pin my half lap joints. I used a dowel cutting jig that I made for my router table.
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I then cut the dowels a little longer than I needed and glued and hammered them into place.
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While waiting for the glue to set up, I was looking for something to do and I decided to try and salvage the custom designer firewood that I made with my first attempt at the wheel sections. I was able to cut plenty of pieces for the front wheels spokes. I got a few for screw ups too. I was glad about that. I hate burning wood when there might be a purpose for it.
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After the glue set up, I used my flush cut saw and trimmed all of the 1/4" dowels.
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And after a little sanding, the wheels look pretty good I think.
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I'm glad I went with the half lap and dowel pinned joint. I think it looks a lot better than just a butt joint.
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Hoping to get some more time in tomorrow but I never know if I will get out there from day to day. I can only hope I guess.

NYWoodturner · Oct 18, 2012

Looking great Ken :yipee:

But I gotta tell ya - The cleanliness of your shop is a little disturbing... :nea:

Scott

Brink · Oct 19, 2012

Ken, I hope you get more shop time. I need something to hold my attention.

I know I'm jumping ahead, but do these wheels get tires? (and I don't mean Goodyears)

kweinert · Oct 19, 2012

Brink said:
Ken, I hope you get more shop time. I need something to hold my attention.

I know I'm jumping ahead, but do these wheels get tires? (and I don't mean Goodyears)

Well, maybe not Goodyears, but they are steel belted, right? :lol:

Very nice build - isn't it interesting how so many of us relax by trying to be precise in our spare time?

Ken

woodtickgreg · Oct 19, 2012

kweinert said:
isn't it interesting how so many of us relax by trying to be precise in our spare time?

Ken

Kenbo · Oct 19, 2012

Brink said:
Ken, I hope you get more shop time. I need something to hold my attention.

I know I'm jumping ahead, but do these wheels get tires? (and I don't mean Goodyears)

My initial thought was that I was going to form some metal around the wheels for the tires and the more I thought about it, the more I didn't want to cover up the half lap joinery that I spent so much time fussing over. I like the joinery and want to keep it exposed, so no tires for this wagon sadly enough.
I did some test cuts of the front wheels today and dry fit some 1/8" hardboard together to verify the size of stock needed. The front tires only have 6 sections so they will not be as fussy to make. I'm looking forward to a good weekend in the shop and some good progress. Here's hoping.
:yipee:

Brink · Oct 20, 2012

Maybe not as fussy to make, but, hexagon isn't as much fun to say as heptagon. :)

scrimman · Oct 20, 2012

Really liking this build, Ken. I was thinking about making a hand cart here recently, even though the scale will be a bit off, this is going to be a great help!

Kenbo · Oct 21, 2012

Okay, the progress.............I cut all the pieces for the front wheels. I then cut the rabbets for the half laps and fitted them together. I sanded off all of the waste areas and glued the wheel sections together. I then cut all the rear spokes to length and marked all the tapers for the hubs of the spokes. I used the disc sander to shape all the tapers. I tried a dry fit and I'm not 100% happy with the fit, but I'm hoping that the center hubs will correct that. I'm not going to scrap them just yet. I then drilled them all to accept the dowel pins. I also routed all the spokes on all 4 sides with a roundover bit. Dry fit them again. Used a primitive jig to drill the holes in the wheels to accept the dowel pins and that was pretty much all I got done.
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