This project is a lot of fun, especially if you are a new Dad, like me. I decided that I wanted to build my son the coolest Radio Flyer wagon I could possibly make, with bigger tires, and a better paint scheme.

I was inspired by scbird94’s thread on Garage Journal about his Radio Flyer projects for his kids, http://www.garagejournal.com/forum/s…ad.php?t=47731

I started with a regular old Radio Flyer wagon that I found on Craigslist for about $25

Started stripping it..

Click through for many many more pics and the completed project!

Primer!

At this point, I really didn’t know what to do next, I knew I wanted some bigger wheels, but I didn’t know how to get them on the axles, how to make them fit, etc. I ended up asking a lot of questions online at this point, went to Northern Tool, and spent a bunch of money

15″ pneumatic tires, some 3/4″ rod for axles and electrical conduit for “lift”, some other metal pieces for sturdiness…

Here are the new tires & wheels, compared to the originals…

I couldn’t wait to put some paint down. I think you will start to get the whole paint scheme if you haven’t got it yet

Here I mocked up the front axle assembly to see how it all fit together…

At this point I had decided I wanted to build a frame, I cut some pieces of flat stock and angle iron into a pretty decent arrangement IMHO. Here I asked some questions: http://www.garagejournal.com/forum/s…ad.php?t=76115 (more detailed pics there)

Got it all welded up by my father-in-law

and painted…

I needed more help to get the axles on correctly, I needed to increase the diameter of the stock axle from .5″ to .75″, and also increase the length.

Here’s a thread where I asked for help on this: http://www.garagejournal.com/forum/s…ad.php?t=77291

Painting has really started now!

Painting the “lift kit”

Used a 1″ long 3/4″ ID spacer here, I had to grind it down quite a bit to make it fit though!

I got in contact with scbird94’s “decal guy” and he was able to send me the negative image stickers I needed to paint the radio flyer logo back on, this worked pretty awesomely! Even though I am a complete noob to painting, I think it came out pretty well!

Masked it off…

Paint…

and Presto!

Final Assembly has begun!

Test fitting the frame!

Everything is painted, starting to bolt it together..

I needed to trim the bolts holding it all together, and the square bits at the top of the bolt won’t pull into the frame so I may need to wallow out the holes a bit more.

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I pulled each bolt out one by one and trimmed to length with my sawzall, got the front tires mounted and got called inside for daddy duty..

Once the little guy was asleep, it was back outside to the wagon…

Cant forget the wooden sides!

Drumroll…….

Ta-daaaaa

A John Deere License plate to finish it off! (Available here: John Deere Auto Tag – Stamped Metal)

I think he likes it

We have taken it out a few times and everyone loves it, well worth the time, effort and money!

The project took about 3 months to complete in between working and helping out at home. Total cost was around $300, biggest expense was the tires & wheels, at $40 per tire/wheel set! (times 4)