How to Make a Replica Wagon Wheel

Prepare a work table or other flat surface large enough to lay out a full sized wagon wheel on., Mark the center point of your work surface, then use this as an anchor point to scribe a line giving you the circumference of your wheel. , Divide the...

37 Steps 1 min read Advanced

Step-by-Step Guide

Step 1: Prepare a work table or other flat surface large enough to lay out a full sized wagon wheel on.

For a 36 inch (91cm) diameter wheel, you will need about 40 inches (101cm) of width and length.

Step 2: Mark the center point of your work surface

,,, If you are using 2X4 nominal width lumber, you can figure the maximum width your rim can be at about 2 3/4 inches (7cm) for reasons you will see as you proceed. , For a 36 inch (91cm) diameter wheel, you will find this length to be about 13 inches (33cm). ,, When you are satisfied the cuts fit, and the overall shape is as desired, fasten each board together either with biscuits, or with wood glue and countersunk wood screws. , Then, fasten it down with a screw to temporarily hold it in place. ,,,, This will be the position you will mark the spokes at, and they should be centered between the joints in the rim of your wheel. , Making sure these are in line will help keep the spokes straight when the wheel is assembled. , Drill holes in the hub about 1 to 1/2 inches (2.5-3.5cm) deep. , You can cut them a little longer than necessary and trim them after the wheel is assembled. , Make sure each fits correctly so that the hub stays centered in the rim. ,

Step 3: then use this as an anchor point to scribe a line giving you the circumference of your wheel.

Step 4: Divide the circle you have scribed into four equal segments

Step 5: either by using a framing square working off the center lines of the table

Step 6: or by measuring the circumference and dividing it by four

Step 7: then measuring these lengths around the arc of the circle.

Step 8: Split each of these arcs once more

Step 9: so you now have the circle divided into eight equal sections

Step 10: being careful to be as precise as you can be...

Step 11: Measure in from the circle toward the center the distance equal to the width you want your rim to be.

Step 12: Measure the length of each segment on a straight line from one side of one arc to the other.

Step 13: Set a miter saw to cut each end of 8 boards of the length you determined in the previous step with an angle of 22.5 degrees on each end

Step 14: with the long points on the same edge of the board

Step 15: and measuring from the long point of one angle to the long point of the other.

Step 16: Lay these pieces of lumber around the circle you have scribed

Step 17: making sure each end fits tightly

Step 18: and the joints between the boards are aligned with the angles you scribed in the earlier step.

Step 19: Build a hub for the wheel by cutting boards large enough for the diameter you desire

Step 20: and center it over your original center point on your work surface.

Step 21: Center the eight sided (octagonal) shape you created earlier on the outer circle you scribe

Step 22: and fasten it down temporarily

Step 23: as well.

Step 24: Set a point on the center mark to scribe the outside and inside circles that form the rim

Step 25: and to scribe the hub circle as well.

Step 26: Use a jigsaw or bandsaw to cut these circles

Step 27: giving the hub and wheel rim their final round shape.

Step 28: Place the rim and hub back in their centered positions and rotate them one half the length of one segment.

Step 29: Mark each end of the spoke location

Step 30: on the wheel and on the hub.

Step 31: Drill holes through the rim of the wheel large enough for the spokes to fit through.

Step 32: Cut dowels long enough to go through the rim and into the hub.

Step 33: Insert the dowels through the rim into the hub

Step 34: gluing them in place.

Step 35: Sand down any rough edges

Step 36: trim spokes (dowels) flush with the outside diameter of the rim

Step 37: and finish the wheel as you desire.

Detailed Guide