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Billy Cart ProcedureA STEP BY STEP GUIDE ON HOW TO BUILD YOUR BILLY CART

supremeincursions.com.auBilly Cart Procedure PAGE01

Materials�BILLY CART PROCEDURE............................................................................................

............................................................................................SupremeIncursions

Rear Axle (two central holes)

Front Axle (one central hole)

Rope

Seat (completed view)

Chassis (long piece)

Wheels

Nylocks (nuts)

BoltsBiscuitsPVA glueWashersScrews

TOOLS REQUIRED: Phillips head screwdriver, flat screwdriver, 19mm spanner, 17mm spanner (Shifter can be used if spanners are unavailable).


Before�You�StartMAKING YOUR SEAT............................................................................................


Step 1 of 9Your seat has 2 flat pieces and 2 triangular pieces. The bottom piece has 2 holes in each top corner and 2 holes in the centre of the seat.

Step 2 of 9Flip the bottom piece on its side and run a little bit of wood glue down the edge over the holes for the biscuits.




Step 3 of 9Place the biscuits in the holes.

Step 4 of 9Lay the bottom piece back down and join the back piece so the holes line up and connect with the biscuits. These pieces will not be sturdy until the side pieces are connected so be sure to hold them together carefully.




Step 5 of 9Very Carefully turn the 2 pieces on their side and run glue sown both sides over the holes where the biscuits go. Place the biscuits in the holes and run glue over the top of them.

Step 6 of 9Place one of the triangular side pieces so that the biscuits line up with holes and connect. Press down carefully so at there are no gaps.




Step 7 of 9Place the smallest screws in the screw holes and screw in with a screwdriver or drill. Wipe down any glue that has leaked out.

Step 8 of 9 REPEATCarefully flip on to the other side and repeat the previous steps.




Step 9 of 9Place the 2 small blocks of wood underneath the bottom piece so that it lines up to the corner neatly. Screw the medium screws into the corner holes all the way until it is flush with the seat. Leave it to dry a little until you are up to using it in one of the steps in the procedure.


Part�01�ATTACHING THE REAR AXLE............................................................................................


Step 1 of 7Take the long piece of timber and place two medium sized bolts down through the two holes at the back as shown.

Step 2 of 7Turn the long piece of timber upside down so the bolts are facing up.


Part�01�ATTACHING THE REAR PIECE............................................................................................


Step 3 of 7Turn the back piece upside down and place onto the bolts. Ensure the rear piece has the silver brackets facing up as shown in thepicture.

Step 4 of 7Place a medium sized washer onto each bolt. Now place a medium sized nylock (nut) onto each bolt and tighten slightly with your hand.


Part�01�ATTACHING THE REAR PIECE............................................................................................


Step 5 of 7When attaching a nylock, always make sure the blue plastic is facing outward.

Step 6 of 7Use a 17mm spanner/shifter and a flatscrewdriver to tighten the nylocks.

Remember....“righty�tighty,lefty�loosey!”


Part�01�ATTACHING THE BACK PIECE............................................................................................


Step 7 of 7Use a flat head screwdriver to hold the head of the bolt steady as you tighten the nyloc with a spanner/shifter.


Part�02ATTACHING THE FRONT AXLE............................................................................................


Step 1 of 4Ensure the long piece of timber is up the right way again before attaching the front axle. Push the bolt down through the hole at the front end of the long piece of timber.

Step 2 of 4Ensure that the bolts at the front and back of the billy cart are facing the same direction.Turn the long piece of timber upside down and place a medium washer onto the bolt.


Part�02ATTACHING THE FRONT AXLE............................................................................................


Step 3 of 4Now turn the front axle upside down and place onto the bolt. Place a medium sized washer onto the bolt as shown in the picture

Step 4 of 4Use a flat screwdriver to hold the head of the bolt steady as you tighten the nyloc with a spanner/shifter.


Part�03ATTACHING THE WHEELS............................................................................................


Step 1 of 4Keep the billy cart upside down to attach all four wheels.

Place a large washer on the axle.

Step 2 of 4Place a wheel onto one of the axles.

Part�03ATTACHING THE WHEELS............................................................................................

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Step 3 of 4Once the wheel is on, place a large washer on the end of the axle. Now place a large nylock onto the axle and tighten with spanner/shifter as shown.

Step 4 of 4Be sure to test whether the wheel still spins whilst tightening. Repeat the process with all 4 wheels.


Part�04ATTACHING THE SEAT............................................................................................


Step 1 of 4Turn the billy cart up the right way before attaching the seat. Place the seat onto the billy cart as shown.

Step 2 of 4Ensure the blocks on the bottom of the seat are resting on the back axle and the seat centred.


Part�04ATTACHING THE SEAT............................................................................................


Step 3 of 4Hold the seat steady and screw the two medium screws down through the holes in the centre of the seat. They should screw directly into the long piece of timber.

Step 4 of 4Carefully turn the billy cart upside down. Screw the two large screws into the holes on the bottom of the back axle. They should screw directly into the blocks.


Part�05ATTACHING THE ROPE............................................................................................


Step 1 of 4Attach the rope using a figure of 8 knot. Push the rope down through one of the holes in the front axle.

Step 2 of 4Pull approx 30cm of rope through the hole and curl the end under to make a loop as shown.


Part�05ATTACHING THE ROPE............................................................................................


Step 3 of 4Curve the end of the rope over the long part then bring it through the loop from behind.

Step 4 of 4Pull tight and see the figure of 8 formation.


The�finished�product!CHECKLIST............................................................................................


Check that all connections are tightAll wheels should spin freelyThe front axle should swivel leftand right freelyThe seat should be secure with allscrews tightDon’t forget to wear your helmet!!


DISCLAIMER...........................................................................................


Please note: The process of building Billy Carts as well as operating Billy Carts provided bySupreme Incursions is to be done strictly under adult supervision at all times. Supreme Incursions do not take responsibility for any injury or harm caused during the process of building or operating the above mentioned Billy Carts.

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