Thomas the Train

After installing a new toilet in a bathroom remodel project I looked at the box and said that looks like Thomas the Train. A grandpa of seven knows what Thomas looks like. (If you have trouble throwing away a cardboard box you may have some hoarding tendencies)
For every 2-3 real projects you should do one just for the heck of it funproject.

If you are a grandpa of seven you may have a collection of power wheels spare parts laying around. Since this is a quick fun project I decided I had to use whatever I had in the workshop.

I used some spare 2x6 and plywood to form a frame to attach the rear axle and the front suspension section.

Drill holes in the 2x6s to slide the rear axle through. I drilled holes and used the original PowerWheels front suspension section mounting holes and screws.

I used the original power wheels steering shaft and steering wheel by drilling a hole at a 45degree angle in the plywood frame floor.
I also built a support bracket for the steering shaft that would mount inside the box with drywall screws. This bracket doubles as a way to mount the cardboard box to the wood frame by sandwiching the cardboard between the frame and the wooden bracket. I also used a piece of plywood to similarly fasten the back of the box to the frame.

I used glue and packing tape to put the box back together. Then cut out openings for the windows and door.

Search google images for Thomas the Train so you have an idea of the paint scheme. I mixed some dark blue and white paint to get close to a Thomas color blue. Then I painted the outside blue.

Thomas has a smiling face on the front. I cut circles out of cardboard and glued them together to get the extended tank look. I glued and used drywall screws (from the inside of the box) to attach the tank/ face.
Ok this step is out of sequence but you get the idea

Thomas has red, black and yellow accent paint and a yellow number 1 on the side.
I added a smoke stack by wrapping a cardboard paper towel roll in black electrical tape, cutting a circular hole in the top and inserting the smoke stack.
This does now use a battery or motors rather this is designed to be powered by dad or big brother or sister.
Ok so it's not perfect but I think the grandkids will recognize Thomas.