Instructions and photography for the Rustic Wheelbarrow is a Do-It-Herself Project from The Home Depot
Cost: $55
Skill Level: Intermediate
Tools Used: Circular Saw, Jigsaw, Drill 1/2" Drill Bit, Measuring tape or Carpenter's Square, Pencil, Safety Goggles, Sand Paper or Sander
Time to Complete: 45 Minutes
Materials:
(1) Crates and Pallet 18" x 12-1/2" x 9-1/2" Large Wood Crate (1000051893; $11.97)
(1) 2" x 8" x 8' #2 Prime Kiln-Dried Southern Yellow Pine Lumber (689238; $5.71)
(3) Pressure-Treated 36" x 2" x 2" Wood Square End Baluster (430792; $0.77 ea x 3 = $2.31)
(1) 1/2" x 48" Wood Round Dowel (148159; $1.72)
(1 box) #8 x 2-1/2" Phillips Square Drive Flat-Head Full Thread Zinc Coated Multi-Material Screw [20 per Box] (571212; $1.98)
(1 pack) #8 x 1" Flat-Head Philips Wood Screws [12 per pack] (285103; $1.18) (optional) Paint or stain
Cut List:
(2) 8" segments cut from one of the Pressure-Treated 36" x 2" x 2" Wood Square End Baluster - Legs
(1) 3.75" segment from the 1/2" x 48" Wood Round Dowel - Wheel Axle
(1) 7" circle cut from 2" x 8" x 8' board - Wheel
Measure and Make Cuts on Cut List:
Measure, mark, and make all of the cuts on the cut list according to the cut diagram. Use a circular saw to cut the two 8” legs from one 36” x 2” x 2” Wood Square End Baluster and the 3.75” Wheel Axle from the 1/2” x 48” Wood Round Dowel. For the 7” Wheel, make a mark in the center of the 2” x 8” x 8’ board about 6” in from the end of the board. Screw one screw halfway into the center mark and wrap a string with one end tied around the screw head and the other end tied around a pencil with 3-1/2” of string between the nail and the pencil and draw the 7” circle. Use a ½” drill bit to drill a hole touching the line of the circle on the outside of the line and then insert a jigsaw into the hole to finish cutting along the outline of the circle. OPTIONAL: Smooth any rough ends with sandpaper or sander.
Drill Holes for Wheel Axle:
Measure and mark the center of both remaining 36” x 2” x 2” Wood Square End Balusters at 1-1/4” from the ends. Using the ½” drill bit, drill a 1/2” hole halfway through the baluster at the center mark of each of the balusters using a slight 5° angle and the drill bit pointing away from short end of the baluster. See diagram.
Drill a 1/2" hole through the center mark of the 7" Wheel.
Attach Balusters to Crate and Wheel
Turn Large Wood Crate upside and align one of the Balusters over the bottom of the crate so that the end of the Baluster with the drilled hole overhangs the end of the crate by 6” and is centered over the second slat on that side while the other end of the Baluster is angled to hit in between the two outermost slats on the other end of the crate, allowing a 12” overhang on that side to act as a handle. Secure Baluster to the bottom of crate using a 2-1/2” screw on each end.
Insert the 3.75” Wheel Axle into the drilled hole on the secured Baluster, slide 7” Wheel onto Wheel Axle, and insert Wheel Axle into the remaining Baluster. With the wheel sandwiched securely between the two Balusters, secure the remaining Baluster to the bottom of the crate centered over the second slat at the wheel end and between the two outermost slats at the handle end using 2-1/2” screws at each end.
Attach Legs
Place the two 8” Legs vertically 3/4” in from the end of the crate on the outside of the Balusters. Secure with one 2-1/2” screw through the Balusters. Turn Wheelbarrow over and secure the legs through the slat on the inside bottom of the crate using one 1” screw into each leg.
Paint or Stain and Finish (optional): Paint or stain and polyurethane especially if using outside.