Construction-

grade
End Loader Dimensions: 7"H × 53∕4"W × 14"L

Shape parts for the rear unit

W
hen it’s time to fill up a toy works much like the real thing. Crafted
dump truck, here’s the right
machine for the job. With a
pivoting body for tight turns, and a
from walnut and maple, it matches our
other Construction-grade toys ( pages
34–35). A kit provides all the specialty
1 Make two photocopies of page 38 and
one photocopy of pages 37 and 39 of
the WOOD Patterns® insert. Prepare a
bucket that lifts and dumps, this rig parts you need [Source, page 36]. 3 ∕4×51 ∕2×63 ∕4" walnut blank for the rear

SUPPORT THE REAR CHASSIS CREATE A GRILL CLAMP THE CAB AND DRILL

E
A

Scrap
A B C
To position the chassis (A) for drilling the axle Make a pass with each edge against the rip fence to A handscrew provides a secure grip on the cab (E)
hole, rest it on a scrap at least 11∕2" thick. Clamp the cut the two outermost kerfs. Reposition the fence while drilling the 1" hole for the window. Back out
chassis to the fence to prevent it from turning. for the next pair of kerfs and repeat. the bit frequently to clear the chips.

32 WOOD magazine November 2013

 2¼"
2½"
1a STEPS (Front view) ¼"
F
1∕8" chamfer ¼ x 1½" smokestack

¼" 1" hole

¼" ¼" hole
C E 3∕8" deep
3∕8"
¼" 2"
B
3"
3∕16" 13∕16"
2"
¼"
3" 1∕8" round-overs
¼"
13∕8" J
C

chassis (A). Spray-adhere a copy of the ¾" 1½"

1" 2½"
Rear Chassis Pattern to the blank, and
bandsaw and sand the chassis to shape. A

2
D 11∕32" hole 2¾" wheels
Drill the 11∕32" hole where indicated ¾"
[Photo A]. Then drill the 3∕16" through- 1"
11∕32" axle peg
hole where shown. 3∕16" hole 25∕8" long

3 Laminate four layers of 3∕4×23∕4×41∕2"

maple for the hood (B) [Drawing 1].
After the glue dries, trim the blank to 1 REAR UNIT ASSEMBLY
3∕8" washer

size [Materials List], and attach copies of

the Hood Side-View and Hood Top-View
Patterns. Following the top-view pat-
tern, cut the kerfs for the radiator grill
[Photo B]. Then drill the 1∕4" hole where
7 Retrieve all of the parts cut to shape
so far, moisten the patterns with
mineral spirits, and scrape them away.
Load up for assembly
Assemble the rear unit of the loader as
shown in Photos D–H below. Allow the glue
shown and bandsaw the bevel following Finish-sand all parts to 220 grit. to dry at least 20 minutes between steps.
the side-view pattern. Chamfer the
edges where shown. GLUE THE HOOD IN PLACE FIRST MAKE A PLATFORM FOR THE CAB

4 Laminate two pieces of 3∕4×2×3" wal-

nut for the steps (C). Resaw and sand
the blank to 13∕8" thick; then, cut the
dadoes for the steps [Drawing 1a]. From
3∕4"-thick maple, lay out and cut the cab
C D

support (D) to size [Drawing 1]. B

5 From a laminated walnut blank, cut A

the cab (E) to size, and attach a copy
of the Cab Side-View Pattern to it. Drill
the hole for the window [Photo C]; then,
chamfer the edges of the window, and
D E
cut the bevel along the front of the cab.

6
Apply glue to the bottom of the hood (B) and While the hood assembly dries, glue and clamp the
Cut the maple roof (F) to size [Draw- clamp it to the rear chassis (A), flush with the edges cab support (D) flush with the top edge of the steps
ing 1], and chamfer the front edge. and set back 5∕16" from the wide end of the chassis. (C), and centered between the ends.

ATTACH THE STEPS TO THE HOOD ADD THE CAB TOP IT WITH THE ROOF

D
E E
B
B

D
A
C C
F G H
Apply glue to the rear face and bottom of the steps Glue and clamp the cab (E) to the hood (B), steps Clamp the chamfered face of the roof (F) to the cab
(C) keeping it at least 1∕4" from the ends. Then center (C), and cab support (D), centering the cab on the (E), centered from side to side and front to back,
and clamp the steps to the chassis and hood. width of the hood. with the chamfer facing down and forward.

woodmagazine.com 33
 P CUT IDENTICAL PARTS THE EASY WAY
10-32 lock nut
10-32
K threaded rod
1" long

I I

I K
1½"
¼"
10-32 lock nut

10-32 2 FRONT UNIT ASSEMBLY I

3∕16" hole
threaded rod
17∕8" long By cutting both arm braces (I) at the same time, you
3∕8" chamfer H guarantee they will be identical. Do the same later
with the bucket sides (M) and arms (P).
A
BUILD UP THE FRONT END

Keep the front

2¾" 2¾" wheels ends flush.
G
11∕32" hole ¾" I

3∕8"
11∕32" axle peg I
2½" 25∕8" long H
1"

3∕8" washer G

J
2a PIVOT BLOCK (Top view) Glue the arm brace/pivot block assembly (H/I) to
the front chassis (G), clamping the parts to your
4" bench while the glue dries.
¾"
3∕16"

3
2" hole
the 11∕32" hole in the chassis where Glue the arm braces (I) to the edges
H shown. Then rout the chamfer on the of the pivot block (H), with their
3∕8"
end of the pivot block. front ends and bottom faces flush. After

2 From 1∕4" maple, cut two 21∕2×23∕4"

¾" the glue dries, glue this assembly to the
blanks for the arm braces (I). Stack front chassis (G) [Photo J].

4
¾" the blanks together with double-faced Laminate maple stock to make a
tape between them, and their ends and 11∕2×11∕2×12" blank. Spray-adhere
Shape parts for the front unit edges flush. Attach the Arm Braces Pat- two copies each of the Rear Fender and

1 Cut the front chassis (G) and pivot

block (H) to size [Drawings 2, 2a].
Drill the 3∕16" hole in the pivot block and
tern to the stack and drill the 3∕16" hole
where shown. Then, cut the braces to
shape [Photo I] and finish-sand them.
Front Fender Patterns along one face of
the blank. Bandsaw and sand the fend-
ers (J, K) to shape. Remove the patterns

Build the whole crew

Purchase plans and kits for these companion projects at
Move earth with the bulldozer (issue 199,
September 2010).
woodmagazine.com/cgtoys.

Reach out and scoop with

Give the crane the excavator (issue 194,
(issue 185, November 2009).
September
2008) a spin on
its base, and
raise and
lower its
bucket with
a crank.

For heavy hauling, fill the dump

34 truck (issue 215, November 2012). WOOD magazine November 2013
 POSITION THE FENDERS
and rout 1∕16"
round-overs on the outside
edges, making sure you end up with
mirrored pairs. Finish-sand the fenders.

5 Temporarily join the front unit

(G/H/I) with the rear unit (A–F)
using a length of 10-32 threaded rod
K

and lock nuts. Dry-fit two wheels and an J

axle peg in the front and rear chassis,
then apply glue to the edge of each
fender and hold or clamp them in place B
for a few minutes until the glue grabs
[Photos K and L]. After the glue dries, K L
repeat the process for the other side. Align the center section of the rear fenders (J) parallel to and 13∕16" below the top of the hood (B). To
position the front fenders (K), refer to the location shown on the Arm Braces Pattern.
Build the bucket and arms
1 Cut the bucket back (L), sides (M),
top (N), and bottom (O) to size, bev-
before assembling the bucket as shown
in Photos M, N, and O.
10-32 threaded rod through the holes in
the upper ends of the arms (P) to align
eling the indicated edges of the back,
top, and bottom [Drawing 3]. Rout a 1∕8" 3 From 1∕4" stock, cut two 23∕4×51∕8"
blanks for the arms (P). Stack the
them, then glue and clamp the arm
spacer between the arms [Photo P].
chamfer along the top front edge of the
bucket bottom.
blanks together as you did with the arm
braces (I), apply a copy of the Arm Pat- 5 Cut the brackets (R) 1∕8" wider than
listed [Materials List]. Apply a Bracket

2 Spray-adhere the Bucket Top Pattern

to the top (N). Miter the two corners,
and drill the holes where shown. Cham-
tern, cut and sand them to shape, and
drill the holes where shown. Separate
the arms and remove the pattern.
Pattern to each bracket and round one
edge as shown in Photo Q. Note the grain
orientation; the rounded and the oppo-
fer both faces of the holes and the front
edge. Finish-sand pieces L–O to 220 grit 4 Cut the arm spacer (Q) to size and
finish-sand it. Slide a 21∕2" length of
site square surfaces should be edge grain,
not end grain.

GLUE THE BACK TO THE BOTTOM ADD THE BUCKET TOP FINISH OFF THE BUCKET

L N

N
M
O L
L M

O
O

M N O
With the bucket bottom (O) resting on your bench, Stand the bucket back and bottom assembly Glue and clamp the bucket sides (M) in place and
glue the bucket back (L) to its top face. Hold the (L/O) on end and glue the bucket top (N) in place, set the bucket aside to dry while you move on to
pieces in place until the glue grabs. sandwiching the bucket back. making the arm assembly.

Rev up the motor grader (issue 208,

Put the scraper to work (issue 219, July 2013). Load and spin with the November 2011).
skid loader (issue 211,
May 2012).

The tractor pulls both the

side-dump and lowboy trailers.
(Find all three pieces in issue
205, July 2011.)

woodmagazine.com 35
 LIFT YOUR ARMS TO ASSEMBLE THEM GIVE SMALL PIECES A HANDLE ATTACH THE BUCKET

P
Q

P P

R L
P Top ends of P Q R
To align the arms (P) and the arm spacer (Q) during To create the radius on the brackets (R), glue each With the bucket and the ends of the brackets (R)
glue-up, rest the pieces on a thick scrap. A length one to a scrap handle. After sanding up to the resting on your bench, press and hold the bucket
of threaded rod aligns the top ends of the arms. pattern line, cut the bracket free. against the brackets.

10-32 10-32 lock nuts Materials List

3 BUCKET AND threaded rod
FINISHED SIZE
LIFT ASSEMBLY P Part T W L Matl. Qty.
1" long
½ x 1½ x 1" Rear and front units
10-32 lock nut A rear chassis 3∕4" 51∕2" 63∕4" W 1
Q
P B* hood 3" 21∕2" 4" LM 1
N
20° bevel C steps 13∕8" 2" 3" LW 1
D cab support 3∕4" 1" 21∕2" M 1
20° bevel
Produced by Craig Ruegsegger
M with Kevin Boyle E cab 2" 21∕2" 3" LW 1
R Project design: Kevin Boyle F roof 1∕4" 21∕2" 21∕4" M 1
10-32 lock nut Illustrations: Lorna Johnson 3∕4"
L G front chassis 21∕2" 23∕4" W 1

5¼" 3∕8" H pivot block 3∕4" 2" 4" W 1

O 10-32 1∕4"
5¼" threaded rods I arm braces 21∕2" 23∕4" M 2
11∕32" 1" long J rear fenders 11∕2" 11∕4" 31∕2" LM 2
20° bevel 20° bevel
K front fenders 11∕2" 3∕4" 15∕16" LM 2
1∕8" chamfer Bucket and lift
27∕16" M
L bucket back 1∕4" 11∕32" 51∕4" M 1
I
M bucket sides 1∕4" 21∕2" 3" M 2
N bucket top 1∕4" 21∕2" 51∕4" M 1
O bucket bottom 1∕4" 27∕16" 51∕4" M 1
¼"
P arms 1∕4" 23∕4" 51∕8" M 2

6
Q arm spacer 1∕2" 11∕2" 1" W 1
10-32
Cut 1" lengths of 10-32 threaded rod 3∕8" 3∕4" 3∕4"
R* brackets W 2
threaded rod and assemble the 17∕8" long
brackets (R) to the arms (P) using lock *Parts initially cut oversize. See the instructions.
10-32 lock nut
nuts [Drawing 3]. Retrieve the bucket Materials key: W–walnut, LM–laminated maple,
(L–O) and finish-sand it. Then apply LW–laminated walnut, M–maple.
glue to the square edges of the brackets Supplies: Double-faced tape, spray adhesive.
Bits: 3∕16", 1∕4", 11∕32" 1∕2", 1" drill bits; 1∕8" round-over, 45°
and glue them to the bucket back (L) chamfer router bits.
[Photo R]. Allow the glue to dry. Cutting Diagram
7 Glue the smokestack [Source] into *Q *R Source
E G Hardware kit: The kit contains all the specialty parts
the hole in the hood (B) [Drawing 1]. (wheels, axle pegs, and smokestack) and hardware (no
Remove the hardware and apply a fin- A lumber) needed to build one end loader. Order kit no.
ish. (We sprayed on three coats of satin RS-00988, $19.95+shipping, 888-636-4478,
aerosol lacquer.) Join the front and rear C H woodmagazine.com/loader.
chassis with a 17∕8" length of 10-32 ¾ x 7¼ x 24" Walnut (1.3 bd. ft.)
threaded rod and lock nuts [Drawing 3]. *Plane or resaw to thicknesses
listed in the Materials List.
Secure the wheels with axle pegs glued  Fellow WOOD® readers inspire creativity
into the chassis (A, G) [Drawings 1 and J, K *F *L *P with toys of their own at
D
*O woodmagazine.com/toygallery.
2], trapping the 3∕8" washers. Finally,
 Prefer slightly larger big-boy toys?
attach the bucket arms (P) to the arm
B B B B *N Check out some 1∕2-scale versions at
braces (I) and brackets (R) with threaded woodmagazine.com/bigmodels.
¾ x 7¼ x 36" Maple (2 bd. ft.) * I *M
rod and lock nuts [Drawing 3]. Your
loader is ready to fill that truck!
36 WOOD magazine November 2013
 Better Homes and Gardens®

WOOD
®
Download this full-size
printable patterns at
woodmagazine.com/zinio222

PATTERNS
November 2013 Issue 222
®

Dear Reader: As a service to you, we’ve included full-size patterns

on this insert for irregular-shaped and intricate project parts.
You can machine all other project parts using the Materials List and
the drawings accompanying the project you’re building.
© Copyright Meredith Corporation, 2013. All rights reserved. Printed in the U.S.A. Meredith Corp., the
publisher of WOOD Patterns®, allows the purchaser of this pattern insert to photocopy these patterns solely
for personal use. Any other reproduction of these patterns is strictly prohibited.

Construction-grade Loader
Page 32

37
 Download this full-size
printable patterns at
woodmagazine.com/zinio222

38
Construction-grade Loader
Page 32

Download this full-size

printable patterns at
woodmagazine.com/zinio222

39