Building a Full Size Railroad Cart

Richie C.OGR Forum Member SUPPORTING MEMBER

Wanted to add a railroad cart coffee table for my playroom and didn't see anything I liked on the net or that was reasonable in price, so I decided to build my own. For the top, I could have just fit a few boards together and used cleats to hold them together, but Lowes sells large planks in different sizes for less than the cost of stick building the top, so I bought a 3/4" thick pine plank that is 48" long and 16" wide. When I add the thickness of the 1 X 6 side panels on each side, the overall width will be 17 3/4", which is the right size for the location the cart will be located in. The total cost should come in right around $125.00, excluding the cost of paints, stains and finishes which I already have; with the cost of the wheels being the highest.

I wanted the "look" of real boards for the top of the cart, so I routed out a few lines with an 1/8" bit set to a 1/4" depth to simulate the look of real boards for the top. I then cut and assembled the sides and ends to the top as one big box with glue and screws set below height so no screw heads would show.

I added a support at each end underneath and then inserted an additional support near each end that lines up with the mounting holes for the 8" diameter vintage-looking caster wheels that I ordered on-line. I'm in the process of painting and weathering those.

I filled the screw holes with wood filler and then sanded everything smooth.

Next step will be staining, finishing and antiquing the top and sides.

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10/5/2010:48 AM

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Richie C.OGR Forum Member SUPPORTING MEMBER

Got the cart stained, poly'd and "distressed".

I then added some corner braces and the "steam punk" handle and put a Lionel clock, train and lantern on top. The handle and caster wheels were weathered, as well.

Would make a nice winter project if you have the space.

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10/16/2011:49 AM

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BillYo414OGR Forum Member SUPPORTING MEMBER

That's a sharp looking cart! I would love to do something like this after I get my table built.

10/16/2012:22 PM

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rattler21OGR Forum Member MEMORIALIZED MEMBER

Richie, Do the casters swivel? If so, which pair, the pair nearest the handle or furthest from the handle? Thank you, John

10/16/2012:57 PM

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Richie C.OGR Forum Member SUPPORTING MEMBER

John - all 4 casters swivel - they appear/feel like ball bearing swivels. I have the wheels rotated towards the inside so they don't stick out and somebody potentially trip on them. They are cast iron and very heavy. Cost was $15 per caster and they were the most expensive part of the build.

Bill - thanks. Total cost ended up around $140.00. About the only thing that I would do different is use 2 X 4's for the four interior supports (see pic) as they have a larger surface area for the screws that hold the casters in place. The 1 X 4's were fine, but using large screws (12 X 2") in only 3/4" wide boards, I had to be very careful about making sure I was drilling the pilot holes perfectly straight down. I also hit a couple of the horizontal drywall screws I had used to secure the interior supports to the frame so, next time, I'd mount them a little further down the side. Luckily, I was able to drill right through the drywall screws, but a lot of time they can kick the drill bit to the side and out the side of the board.

I'd also consider going to a 20" wide plank for the top instead of the 16" I used, so the mounted casters aren't quite so close together, but I didn't really have the extra space.

I almost cried though when I had to take a hammer and gouge to a new piece of wood to "distress" it. I ended up using a brown and black Sharpie to color in most of the distressed areas to give them an aged look before putting on the satin finish poly, but left a few new.