How to Build a Simple Wheelbarrow

Use your power drill and 3/4-inch metal bit to make holes at both ends of a small empty refrigerant tank. The tank will serve as your wheelbarrow wheel. Slide a piece of 3/4-inch steel conduit through the holes in your refrigerant tank. The conduit should extend about 3 inches past the end of the tank on both sides. Use your welder to fasten the conduit to the tank. The conduit will serve as your axle.

Use your circular saw to cut a 2-by-4 inch stud into two 50-inch long pieces. These pieces will serve as your wheelbarrow handles. Use a wood file to carve away wood at one end of each stud, and create whatever size and shape handle you prefer.

Lay your two handles on a flat work surface, so that broad sides of each stud are facing upward and downward. Raise the handle end of each stud 5 inches off the ground to simulate the angle the handles will rest at when installed on the wheelbarrow. Use your power drill to make a 3/4-inch pilot hole through each stud, about 3 inches from the non-handle end, and directly at the center. These holes will serve as your axle mounts.

Drill two 1/4-inch pilot holes into the studs from the top down, with one on each side of the axle mounts. Insert 1/4-inch carriage bolts and nuts, sandwiching washers on both ends. These bolts will serve as a clamp that will prevent the wood around your wheelbarrow axle from splitting when in use.

Drill another 1/4-inch pilot hole into the side of each handle stud about 9 inches further up from your wheel mounting holes.

Mount your wheel through the two pilot holes you drilled in step 3 by sliding the ends of your conduit axle rod through on both sides.

Cut a 1-by-2 inch piece of lumber to a length of 19-1/2 inches, and nail it to both handle studs about 1 inch behind the wheel. Use your hammer to drive nails through the handle studs and into the wooden brace.

Use your circular saw to cut a 2-by-4 inch stud into two pieces, 34 inches each in length. These will serve as your wheelbarrow legs and bucket supports. Use your drill to make two side by side 1/4-inch pilot holes though each piece, about 23 inches from one end. Drill matching holes in the handle studs about one-quarter of the way from the wheel end. Use your 1/4-inch bolts, washers and nuts to fasten these leg studs to the handle studs at a 145 degree angle, with the longer end protruding above the handles where it can support the bucket.

Cut two 2-by-4 inch studs to a length of 23-3/4 inches. These will serve as your front and rear braces. Fit one brace on the underside of your handles, so that it leans against the legs. Place the other brace against the ends of the bucket supports. Drill two pilot holes into each mounting location, and use carriage bolts, washers and nuts to fasten the rear brace in place, and 1/4-inch lag bolts for the front brace.

Use your circular saw to cut a 1-by-12 inch wooden board into four pieces, each with a length of 28 inches. These will serve as the bucket bottom. Lay all four pieces along the open "V" shape formed by the handles and the bucket supports. Use your screw gun and wood screws to fasten them in place. Leave a small space in the seams between your wooden planks to allow for drainage. This can prevent standing water and subsequent rot.

Cut two 1-by-10 inch boards at a length of 43 inches each. These will serve as the bucket sides. Fasten the two bucket sides to the ends of your bucket bottom planks, with your screw gun and wood screws.

Use a paint brush to apply wood sealer to the wheelbarrow. Sealer will help prolong the life of your construction and defend it against the elements when left outside. Follow the instructions provided by the sealer manufacturer for the best results.