- 1). Form two 15-by-20-inch and two 15-by-15-inch pieces of 3/4-inch plywood into a box with the ends of the 15-by-15-inch pieces making the corners on the inside edge of the 15-by-20-inch pieces.
- 2). Hold the box together with a band clamp. Predrill three evenly spaced pilot holes sized for 1-5/8-inch wood screws through the sides of the 15-by-20-inch pieces of plywood into the ends of the 15-by-15-inch pieces.
- 3). Apply a line of glue around the bottom of the insides of the box. Slide a piece of 13.5-by-18.5-inch 3/4-inch plywood into the box and push it right down to the bottom for the base of the box. Secure with finishing nails hammered every three inches around the bottom of the box into the sides of the base.
- 4). Position two planks of 20-inch-long 1-by-2 lumber halfway along the top of the 20-inch sides of the box, at a 45-degree angle upward for the handles of the lawn cart. Secure with four wood screws per handle. Where the handles reach their highest point will be the rear of the cart.
- 5). Scribe a 5-inch-diameter circle onto two pieces of 5-inch-by-5-inch 3/4-inch plywood. Use a scroll saw to cut out the circles for the wheels of the lawn cart. Drill a hole sized for 2-inch bolts through the center of each wheel.
- 6). Hold the wheels up to the side of the cart at the front, at the opposite end of the cart from where the handles reach their highest point. Position the wheels so that the center of each wheel is around 3 inches in and up from the front corner of the box, and drill a hole through the box side at this position.
- 7). Fit a washer over the end of a bolt, then insert the bolt into the hole in one of the wheels. Fit another washer over the bolt, then insert the bolt through the hole in the cart. Fit a third washer over the end of the bolt, then secure the bolt with a nut on the inside. Repeat with the other wheel.
- 8). Finish the cart with your desired wood finish -- paint, stain, varnish or wax are all acceptable. If you want to plant directly into the lawn cart and have it as a decorative feature, avoid chemical finishes that may damage the plants.
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