Wagon 2.0 progress, I was tasked with adding a paint job to this:





but had a couple of issues to address first prior to paint. The dropped axle design lacked lateral strength of an I-beam, so we ordered some 1/8 x 1/2 flat bar to cap the top and bottom, adding much needed strength. Next, the frame hoop was produced with limited tooling availability, and the corners made use of pie-cuts that some still remained and would show through the paint. I attempted to weld some of these closed, but realized it would be quicker to remake the hoop.





Always one to make tools into multiple use, the new tubing corners were bent on our buffer stand "radius brake"


https://www.youtube.com/watch?v=8oyTLqpeXSk














The rear "axle" stanchions had been bolted on using rivnuts, but I was worried the side wall of the tubing may deflect from weight in the wagon. So in true Robert overbuilding form, some threaded standoffs were turned into a sleeve that would weld on both sides of the tubing for less stress upset.











Both ends were ground flush prior to welding..





Welding the front end to the new frame hoop...





Next, to clean up the front end components a bit in order to add oilite bushings...























With spindle perches welded to the ends of our "I-beam" front end... a test fit of all the bits..





And here with our center link added, the last fabrication detail needed will be the handle.. to be continued...


https://www.youtube.com/watch?v=eE6G7vHhYmc