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Excavator
Construction-Grade

Kids (and grown-ups) will dig

this scaled-down scooper.

P ut this toy and a pile of marbles or Legos in front of children and watch them while away the time scooping
and moving them. The excavator
excvator shares design elements with the crane DP-00594 [More Resources, page 8].

DP-00737 ©Copyright Meredith Corporation 2009 Page 1 of 10

 at a glance shop tip
■ Overall dimensions: 193 ⁄16" long × 6" wide × 6 7 ⁄16" high with the bucket at
ground level Cutting threaded
■ Bucket capacity: Approx. .00008 cu. yd. (3.75 cu. in.) rod: It’s a snap
■ Boom reach: 14"
■ Dig depth: 81 ⁄4" Cut 4-, 6-, 8-, and
■ Engine rated at 1 kidpower, continuous duty 10-gauge threaded rod
quickly and cleanly with a
pair of wire stripper/

4
We start with a bucket, Make two copies of the Boom Side cutters. Thread the rod
then boom Pattern and one copy of the Jib Pat- into the appropriately

1 From 3 ⁄4"-thick stock, cut the tern page10. Spray-mount them to your sized hole in the tool,
bucket bottom (A) and bucket stock, then cut and sand the jib (D) and below, then shear it to
back (B) to size [Materials List , page 7]. boom sides (E) to shape. Spray-mount a length. Twist the rod out
Glue the pieces together with the copy of the Cab Pattern page 9, to a piece of the cutter, and the tool
grain running in the same direction of 11⁄2"-thick stock (or laminated 3⁄4" cleans up the cut threads.
[Drawing 1]. stock) and cut the cab (F) to shape. Drill Find stripper/cutters at

2 Make two copies of the Bucket Side the holes where indicated on the pat- most hardware and
Pattern from page 9, and set one terns, then chamfer the edges. Sand the home-improvement stores
aside. Trim the other along the dashed parts to 150 grit, then glue the Shaker for about $20.
lines around parts A and B, and adhere peg into a boom side [Drawing 1]. Note:
the pattern to the bucket assembly (A/B). The peg can go on either boom side. Measure from end
Cut away the inside waste at the band-
saw [Photo A]. 5 Apply one copy of the Jib Lever Pat-
tern and two copies of the Boom
of rod to inside
face of jaws.

3 Cut the bucket sides (C) to size and

apply the remaining Bucket Side Pat-
tern to one. Stack the bucket sides with
Pivot Pattern to 1⁄2" stock, and cut the jib
lever (G) and boom pivots (H) to shape.
Cut the jib pistons (I) to shape following
their edges flush and drill holes where the Jib Piston Pattern. Sand away the pat-
indicated. Cut two 23⁄4" lengths of terns and any mill marks with 150-grit
threaded rod [Shop Tip, at right], and sandpaper. Cut five lengths of threaded
screw an acorn nut onto one end of rod for the boom [Drawing 1], then set
each. Glue and clamp the bucket sides to the bucket (A/B/C), boom pieces (D, E,
the bucket (A/B) [Photo B]. G, H, I), and cab (F) aside.

Acorn nuts
C

B
A

A
C

B
A B
cut the bucket to shape cross this off your bucket list
Bandsaw just outside the line inside the Align the dashed lines on the pattern with
bucket, then sand to the line using a spindle the edges of the bucket (A/B). Threaded rod
sander. Use a 1⁄8" or 1⁄4" blade to cut this curve. through the bucket sides (C) aligns them.

Page 2 of 10
Turn your attention
to the pivot table
and drill the axle holes [Photo E].

2 Adhere two copies of the Wheel 4 Spray-mount two copies of the Wheel
Cover Pattern to 1⁄2" stock and cut the

1 Cut to size and shape the pivot table

(J), counterweight (K), and catwalk
(L). Cut the engine cover (M) to size
Spacer Pattern to 3⁄4"-thick stock. Cut
the wheel spacers (O) to size, and drill
the holes. Glue the spacers to the chassis
wheel covers (Q) to size and shape. Glue
the covers to the chassis [Drawing 3a,
Photo F].
[Drawing 2] and apply a copy of the (N), centered between the ends and
Engine Cover Pattern to it. Drill the holes
flush at the bottom [Drawing 3a]. 5 If needed, sand the axle pegs to fit
snugly in the axle holes in the chas-
in the engine cover, counterweight, and

overs on the counterweight and engine

3
pivot table [Drawing 2]; then rout round-
Cut the turntable (P) to size and
chamfer the top edges [Drawing 2].
Glue and clamp the turntable to the
sis (N) and wheel spacers (O). Cut 1⁄8"
from the 7⁄8"-long pegs [Drawing 3]. Test
the fit of the wheels and axles, but don’t
cover. Glue the smokestack into the chassis, centered. After the glue dries, glue them in place.
engine cover and set the cover aside. drill through the turntable, using the

2 Glue the catwalk (L) to the pivot

table (J) with the
top and front ends
hole in the chassis as a guide.

flush [Drawing 2].

Then, glue a boom
L
pivot (H) to the pivot
table [Photo C]. After
J
the glue sets, glue the
remaining boom pivot H
in place [Photo D].

3 Glue and clamp

the counterweight
(K) to the pivot table
J
H
(J) against the boom
pivots (H) and cen-
tered side-to-side. To
E
center the counter-
3/8" L
weight hole over the
hole in the pivot table, Threaded rod
push a bolt through
both holes. C D

4 Assemble the jib Glue the first boom pivot

(D), boom sides Measure to position the first boom pivot (H).
(E), jib lever (G), and Glue the pivot in place with the narrow end
glue the second boom pivot
Use a boom side (E) and threaded rod to
position the second boom pivot (H). The
jib pistons (I) with flush with the end of the pivot table (J). boom should move with very light resistance.
threaded rod and
acorn nuts [Drawing 1].
Attach this assembly
to the boom pivots
(H). Then screw (don’t
Align centerlines.
glue) the cab (F) to the
pivot table (J). This
allows for removing
the cab to adjust resis- N P
tance on the boom
arm.
Q
Fabricate a N
massive chassis
1 Cut the chassis (N)
to size and lay out
the tapers and axle
11/32" brad-
point bit
O
holes on both sides
[Drawing 3a]. Drill the Fence
3⁄8" hole and counter- E F
bore centered on the drill axle holes attach the wheel covers
bottom [Drawing 3]. Use a drill-press fence to position the chassis Align the top of the wheel covers (Q) with the
Then cut the tapers (N). Drill halfway through one side, then flip bottom edge of the chamfer on the turntable
the chassis over and complete the holes. (P) and centered on the turntable’s length.
Page 3 of 10
 1½" 1⁄16" chamfers

1 boom 5⁄8" counterbore

½" deep F
2¼"

10-32 threaded rod 1¾"

10-32 threaded rod 2½" long
1¼" long ½"
G
H
10-32 acorn nut
1¾" Shaker peg
¼" hole
¼" deep E
I ¼"
I
½" E
10-32 threaded rod
1¾" long
1"
10-32 10-32 threaded rod
washer 1¼" long
H 3⁄16" holes
1⁄16" chamfers
1¾"
10-32 lock nut

10-32 threaded rod D

1¾" long
10-32 acorn nut
¼"
10-32 nut

10-32 threaded rod 2¾" long C

2"
10-32 acorn nut
B
A
2"

C 2¼"

Page 4 of 10
 5⁄8 x 1" smokestack

#8 x 1" R.H. wood screw

¼" round-over 1¾"

2¾"
M
2 exploded view
5⁄8"
6"
3½" 3⁄8"

1½"
I K
D 1" hole, centered ¼" round-over

3⁄8" lock nut

E
3⁄8" washer
C
A

3⁄8"
23⁄8" 6"
7⁄16" 3⁄8"
Shank hole, countersunk J
on bottom face 3¼" 3⁄8" hole,
L centered
¾"
#8 x 1" F.H. wood screw ¼" chamfer
P
3⁄8" hole,
1½" nylon washer 3" centered
3"

N
O

1½" 5"
Q
3⁄8" washer

3⁄8 x 3" hexhead bolt

Page 5 of 10
 ¾" 1" counterbore
3 chassis ¼" deep with a
3⁄8" hole centered inside
11⁄32" hole
3"
1¼" single 3⁄8" washer 7⁄32" hole
wheel
2" tandem wheel

¼" washer ¾" N

O

4"

7⁄8" axle peg 21⁄8" axle peg

3a chassis side view

1½" ¼"

½" 11⁄32" hole

Location of part Q Filename: 194 Excavator 2
1½" 3-25N
¾"
LeMoine/Jeff
2" Location of part O Kevin 4-14 ¾"
Kevin 4-27
_#100672424.ai 8" Kevin 5-15
RL 5-26

Page 6 of 10
 F* cab 1 ⁄2" 1 ⁄4" 2 ⁄4" W 1
G* jib lever 1⁄2" 1⁄2" 3" W 1
H* boom pivots 1⁄2" 1" 13⁄4" W 2

Materials List I* jib pistons 1⁄4" 1⁄2" 71⁄4" W 2

Materials TList
Part
FINISHED SIZE
W L Matl. Qty.
Body
FINISHED SIZE
Part T W L Matl. Qty. J pivot table 1⁄2" 31⁄4" 6" W 1
Boom
K counterweight 11⁄2" 31⁄2" 6" M 1
A* Boom
bucket bottom 3⁄4"
2" 21⁄4" M 1
A* bucket bottom 3⁄4" 2" 21⁄4" M L catwalk 1⁄4" 11⁄4" 31⁄2" W 1
B* bucket back 3⁄4" 2" 2" M 11
M engine cover 1⁄2" 13⁄4" 23⁄4" W 1
C*B*bucket
bucket back 1⁄4" ⁄4"21⁄2"2" 31⁄22"
3
sides " WM 2 1
Undercarriage
D*C*jibbucket sides 1⁄2" ⁄4"11⁄42" ⁄2" 633⁄4"⁄2" M
1 1 1 W 2
1
N chassis 11⁄2" 3" 8" W 1
E*D*boom
jib sides 1⁄2" ⁄2"33⁄1
1⁄4"
1136⁄4"⁄4" M
1 3 M 1
8" 2
E* boom sides 1⁄2" 33⁄8" 113⁄4" M 2 O* wheel spacers 3⁄4" 3⁄4" 4" M 2
F* cab 11⁄2" 13⁄4" 21⁄4" W 1
F* cab P turntable 1⁄2" 3" 3" W 1
1⁄21
1⁄2" 13⁄4" 21⁄4" W 1
G* jib lever " 1⁄2" 3" W 1
G* jib lever Q wheel covers 1⁄2" 11⁄2" 5" W 2
1⁄2" ⁄2" 1" ⁄2" 13⁄4"3"
1 1 W 1
H* boom pivots W 2
H* boom pivots *Parts cut from blanks using patterns. See the instructions.
1⁄4" ⁄2" 1⁄2"1" 71⁄1
1 3⁄4" W 2
I* jib pistons 4" W 2
I* jib pistons 1⁄4" 1⁄2" 71⁄4" W 2 Materials key: M–maple; W–walnut.
Body
Body Supplies: Spray adhesive, #8×1" flathead wood screw
J pivot table 1⁄2" 31⁄4" 6" W 1 (1), #8×1" roundhead wood screws (2), blue thread lock.
J pivot table 1⁄2" 31⁄4" 6" W 1
K counterweight 11⁄2" 31⁄2" 6" M 1 Bits: 1⁄4" round-over, 45° chamfer router bits; 5⁄8",
K counterweight 1 11⁄2" 131⁄2" 1 6" M 1 1" Forstner bits; 9 ⁄16" drill bit.
L catwalk ⁄4" 1 ⁄4" 3 ⁄2" W 1
L catwalk 1⁄4" 11⁄4" 31⁄2" W 1
M engine cover
M engine cover
1⁄2" 13⁄4"
1⁄2" 13⁄4"
23⁄4"
23⁄4"
W
W
1
1 Source
Undercarriage Wood/hardware kit: Contains the following wood
Undercarriage parts and hardware: 2" tandem wheels (4), 21⁄8" axle pegs
N chassis 11⁄2" 3" 8" W 1
N chassis 11⁄2" 3" 8" W 1 (4), 11⁄4" single wheels (6), 7⁄8" axle pegs (6), 13⁄4" Shaker peg
O* wheel spacers 3⁄4" 3⁄4" 4" M 2 (1), 11⁄2" nylon washer (1), 5⁄8×1" smokestack (1), 10-32 lock
O* wheel spacers 3⁄4" 3⁄4" 4" M 2
nuts (2), 10-32 acorn nuts (12), 10-32 nuts (4), 10-32×12"
P turntable 1⁄2" 3" 3" W 1
P turntable 1⁄2" 3" 3" W 1 threaded rod (2), 10-32 washers (2), 1⁄4" washers (6), 3⁄8"
Q wheel covers 1⁄2" 11⁄2" 5" W 2 washers (6), 3⁄8×3" hexhead bolt (1), 3⁄8" lock nut (1). Order
Q wheel covers 1⁄2" 11⁄2" 5" W 2
*Parts cut from blanks using patterns. See the instructions. kit
kitno. 3200, Meisel
RS-00737, Hardware Specialties, 800-441-9870,
woodmagazine.com/excavator
*Parts cut from blanks using patterns. See the instructions. meiselwoodhobby.com.

Materials key: M–maple; W–walnut.

Cutting Diagram
Supplies: Spray adhesive, #8×1" flathead wood screw
(1), #8×1" roundhead wood screws (2), blue thread lock. * I *M
Bits: 1⁄4" round-over, 45° chamfer router bits;*5⁄H
8",
*G
1" Forstner bits; ⁄16" drill bit.
9
*C *Q *Q
Source *C *J N N *P
Wood/hardware kit: Contains the following wood
parts and hardware: 2" tandem wheels (4), 21⁄8" axle pegs * L
F
(4), 11⁄4" single wheels (6), 7⁄8" axle pegs (6), 13⁄4" Shaker peg
¾ x 5½ x 36" Walnut
(1), 11⁄2" nylon washer (1), 5⁄8×1" smokestack (1), 10-32 lock (1.5 bd. ft.)
nuts (2), 10-32 acorn nuts (12), 10-32 nuts (4), 10-32×12"
threaded
B O washers
rod (2), 10-32 * D (2), 31⁄4" washers (6), 3⁄8"
washers (6), ⁄8×3" hexhead bolt *
3 (1), ⁄8" lock nut (1). Order *
kit no. 3200, Meisel Hardware E 800-441-9870, E
Specialties,
K K
A
meiselwoodhobby.com.
¾ x 5½ x 48" Maple (2 bd. ft.)
*Plane or resaw to the thicknesses listed in the Materials List.
Page 7 of 10
Finish and assemble
1 Remove the wheels, axles, and all of the hardware
and apply a finish. (We sprayed on two coats of
polyurethane, buffing between coats with a 320-grit
sponge.) After the finish has dried, reassemble the
boom (A/B/C, D, E, G, I) using thread lock on all acorn
nuts. Attach the boom assembly and cab (F) to the
pivot-table assembly (H/J/K/L).

2 Place a wheel and a washer on each axle peg and

glue the pegs in place, making sure no glue gets on
the wheels and that the wheels turn freely [Drawing 3]. Nylon
After the glue dries, bolt together the chassis assembly washer
and pivot table/boom assembly [Photo G]. Then screw
the engine cover (M) in place [Drawing 2]. 3⁄8" lock nut 3⁄8 × 3" hex-
3 Power up the “engine” with cookies and milk,
point the kids toward the marble quarry and let
them dig in.
M
head bolt

Written by Craig Ruegsegger with Kevin Boyle

Project design: Jeff Mertz
Illustrations: Roxanne LeMoine; Lorna Johnson
Graphic design: Lorna Johnson

The purchase of these plans does not

transfer any copyright or other ownership
interest in the plans, the design, or the
G
finished project to the buyer. Buyer may
neither reproduce the plans for sale nor offer
ALMOST READY TO SCOOP
for sale any copies of the finished project. To remove wobble but allow the assemblies
to pivot, snug a lock nut onto the bolt joining
them. A nylon washer reduces friction.
MORE RESOURCES
RELATED ARTICLE
■ "Contractor-Grade Mobile Crane," issue 185 (Sept. 2008) $
/cgtoys)
($ = Download this article from woodmagazine.com/plans for a small fee. Type "crane" in the Search box.)

Page 8 of 10
 JIB PISTONS
JIB PISTONS
3⁄16" hole
3⁄16" hole I
3⁄16"I hole
I JIB PISTONS
FULL-SIZE
FULL-SIZE PATTERN
PATTERN ½" ½"
FULL-SIZE JIBPATTERN
(2PISTONS
needed) ½"
5⁄32" shank hole, 3⁄16" hole¼" round-over I (2 needed)
JIB(2PISTONS
H FULL-SIZE PATTERN
3⁄16" hole needed)7¼" ½"
countersunk 1" I FULL-SIZE PATTERN
3⁄16"¼"
holehole (2 needed)
7¼" ½"
BOOM PIVOT 7¼"
(2 needed)
FULL-SIZE PATTERN 7¼"
7¼"
(2 needed)
M 1¾"
3⁄16" hole
3⁄16" hole
ENGINE COVER
5⁄32" shank hole, ¼" ¼" round-over
round-over 3⁄16" hole
5⁄32" shank hole,
FULL-SIZE PATTERN
5⁄32"countersunk
shank hole,
countersunk ¼" round-over 3⁄16" holeH H
5⁄32" shank hole,
countersunk ¼" hole ¼" hole¼" round-over 1" 3⁄16"1"hole H
5⁄32" shankcountersunk
hole, ¼" round-over
¼" hole 1" BOOM BOOM H PIVOT
PIVOT
¼" hole 1" BOOM
FULL-SIZE PIVOT
FULL-SIZE PATTERN
PATTERN
HBOOM PIVOT
1¾" 1¾"countersunk
2¾" ¼" hole 1" FULL-SIZE PATTERN
1¾" BOOM (2 (2
needed)needed)
PIVOTPATTERN
FULL-SIZE
1¾" M (2 needed)
1¾"
M FULL-SIZE PATTERN
1¾"(2 1¾"
needed)
M (2 1¾"
needed)
ENGINE
ENGINE COVER M COVER 1¾"
ENGINE
FULL-SIZE M COVER
FULL-SIZE
PATTERNPATTERN 1¾"
WHEEL SPACER FULL-SIZE ENGINE
PATTERNCOVER
7⁄32" holes
ENGINE COVERPATTERN
FULL-SIZE G
FULL-SIZEFULL-SIZE PATTERN ½" JIB LEVER 3⁄16" hole
2¾" 2¾"
PATTERN 2¾" O FULL-SIZE PATTERN
(2 needed) 2¾"
2¾" 3"
4"

WHEEL WHEEL SPACER

SPACER 7⁄32" holes
7⁄32" holes To ensure full-size patterns are correct
WHEEL SPACER
FULL-SIZE
FULL-SIZE 7⁄32" holes G yourGprinter should be set to print
size,
¾" ¾" WHEEL SPACER 7⁄32" holes 3½" ½"
½" atG100% JIB
JIB(not
LEVER LEVER
fit to page). Measure 3⁄16" hole
3⁄16" hole
1⁄16" chamfers FULL-SIZE
PATTERN
PATTERN ½" JIB GLEVER 3⁄16" hole
¾" WHEEL SPACER
FULL-SIZE
PATTERN
7⁄32" holes
O O FULL-SIZE
FULL-SIZE
full-size toPATTERN
PATTERN
patterns verify size.
¾" (2 needed)
(2 needed)
FULL-SIZE O
½" G
FULL-SIZE JIB LEVER
PATTERN 3⁄16" hole
¾" PATTERN
(2 needed) ¾" O ½" JIB LEVER
FULL-SIZE 3" PATTERN
3" 3⁄16" hole
1" hole PATTERN(2 needed) 4" 4" O FULL-SIZE PATTERN
3"
(2 needed) fi 1"
4" ‹ ‡3"
4" 3" 3⁄16" holes
4" C
BUCKET SIDE 3½" 3½"
1⁄16" chamfers
1⁄16" chamfers 3½"
1⁄16" chamfers FULL-SIZE 3½"
5⁄8" hole1⁄16" chamfers ¾" PATTERN3½"
½" chamfers
deep1" hole 1" hole 2½" ¾"
1⁄16" ¾" (2 needed)
1" hole ¾"
1" hole
1" hole F 2¼"
¾" 3⁄16" holes
3⁄16" holes
A C C 3⁄16" holes
7⁄64" pilot
2¼"hole C 3⁄16" holes
2¼" BUCKET
BUCKET C SIDESIDE 3⁄16" holes
2¼" BUCKET SIDE
FULL-SIZE
CFULL-SIZE
1¾"
2¼" 5⁄8" hole
5⁄8" hole BUCKET
FULL-SIZE2" SIDE
2¼" CAB 5⁄8"
½"hole ½" deep
deep 2½" 2½" BUCKETPATTERN
B PATTERN
SIDE
FULL-SIZE
PATTERN
½" deep5⁄8" hole 2½" (2 needed)
(2 needed)
FULL-SIZE
PATTERN
FULL-SIZE PATTERN 5⁄8" hole½" deep 2½" (2 needed)
F F 2½" 2¼"
2¼" ¾" PATTERN
(2 needed)
½" deep
F 2¼" A A(2 needed)
7⁄64" hole
7⁄64" pilot pilot hole F 2¼" A
7⁄64" pilot hole F 2¼" A
7⁄64"
1¾"pilot1¾"hole A 2" 2"
WHEEL COVER
7⁄64" pilot1¾"hole
CAB Q B B 2"
FULL-SIZEFULL-SIZE CAB1¾"
PATTERN ½" B 2"
FULL-SIZE CAB
1¾" PATTERN PATTERN B 2"
(2 needed)
FULL-SIZE PATTERN CAB B
CAB
FULL-SIZE PATTERN ¾" ¾"
Filename: 194 Excavator 4 (5-26)
FULL-SIZE PATTERN
5" ¾"
3-25 ¾"
¾"
Kevin 4-27
File: 194ExcaPP1_#100.ai
WHEEL WHEEL
COVERCOVER Kevin 4-14
Date: 5/09 WHEEL
FULL-SIZE COVER
FULL-SIZE PATTERNQ Q
PATTERN ½" ½" Kevin 5-15
FULL-SIZEWHEEL COVER
PATTERN Q ½" RL 5-26
Lorna J. WHEEL (2 needed)
(2 needed)
COVER
FULL-SIZE PATTERN Q ½"
(2 needed) Q
FULL-SIZE PATTERN
(2 needed) 5" 5" ½" Filename:
Filename:
Filename: 194 Excavator
194 Excavator
194 Excavator 4 (5-26)44 (5-26)
(5-26)
3-25
(2 needed) 5"
Filename:
3-25 3-25 194 Excavator 4 (5-26)
3-25 Filename: 194 Excavator 4 (5-26)
5" Filename: 3-25
194 Excavator
Kevin 4-27 4 (5-26)
File: 194ExcaPP1_#100.ai
File: 194ExcaPP1_#100.ai 5" 3-25
Kevin
Kevin
Kevin 4-27 4-27
Kevin 4-14
Kevin 4-14
Kevin4-27
4-14
File: 194ExcaPP1_#100.ai
Date: 5/09 Kevin4-27
5-15
Date:File:
5/09
194ExcaPP1_#100.ai Kevin Kevin
Kevin4-14
Kevin
5-15 5-15
Page 9 of 10
Date:
File: 5/09 J.
Lorna
194ExcaPP1_#100.ai
Kevin
Kevin RL 5-26
Kevin
5-15
4-27
RL 5-26 RL 5-26
4-14
Lorna J. 5/09
Date: Kevin 4-14Kevin 5-15
RL 5-26
Lorna5/09
Date: J. Kevin 5-15RL 5-26
Lorna J. RL 5-26
 3⁄16" hole
1⁄16" chamfers *Drill ¼" hole on one boom side only.

*¼" hole
¼" deep

1¼"
E
BOOM SIDES
FULL-SIZE
PATTERN
(2 needed)

3⁄16" holes

3⁄16" hole
1⁄16" chamfers

9⁄16"
6¾" holes

9⁄16"
holes

D To ensure full-size patterns are correct

JIB size, your printer should be set to print
at 100% (not fit to page). Measure
FULL-SIZE full-size patterns to verify size.
PATTERN
3⁄16" hole
fi 1"
‹ ‡

3⁄16" hole

Page 10 of 10