GAS PUMP

My grandson, at only three years old, has amassed many toy trucks. He has now recognized the fact that vehicles run on fuel, just like his Dad’s car.
Ergo, the need for a fuel supply source.
To answer the need, Grandpa to the rescue.
The idea of the “Gasolene Pump” was born.
Join me for the journey of this build.

MATERIALS:
24” x 48” - 1/2” SMOOTH Plywood
AKA - Handyboard
72” x 6” - 1/4” Plywood
1” x 8” - 24” White Pine (for discs)
1/4” x 48” Wood Dowel
#6 x 1” Cabinet Screws (box)
Bottle CA GLUE for wood
…………………………………………… 1/4” inside dia. Clear flexible tubing 18”
3/8” inside dia. Clear flexible tubing 24”
1 Quart Red Paint. Gloss
1 Quart Blue Paint. Gloss
Misc. Brushes, tape cleaner
1 Ea. 3 - gang electrical
remodeling box
3 Ea Decora on/off switches
1 Ea 3 - gang switch cover
plate
2 Ea “D” hooks
TOOLS and SUPPLIES NEEDED:
SAFETY GLASSES and DUST MASK
1. Plans and sketches
2. Pencils, tape measure, square, rule
3. Circular Saw
4. Jig Saw or Saber Saw and blades
5. Cordless Drill with Screw Bits and
Miscellaneous drill bits
6. 2” hole saw (used with drill))
7. 5/16”. Wood Spade Bit
8. #6 Countersink drill bit
9. Square corner vise clamp
10. 36” clamps

1. Setup the 24” x 48” - 1/2” plywood on
a workbench or set of saw horses.
2. Using the cut schedule drawing “A”
(Part 1) lay out the pieces to be cut.
3. After laying out Part 1, use circular
saw to cut A, B, C and D. These are
the Front, back, top and bottom
sections of the Gas ⛽️ Pump
4. From the 72” x 6” - 1/4” (see cut
schedule Part 2) cut two (2) pieces
E and F: 28” in length. Use circular
saw to cut these two pieces. These
are the two (2) sides of the Gas ⛽️
Pump.
5. Clamp the 1” x 8” - 24 (part G) onto the workbench. Mark the center points of eleven (11) discs. Refer to Cut Schedule Part 3.
6. Using a 2” hole saw attached to the cordless drill, begin drilling the hole. Once the hole is started (TIP), place the hole saw on the reverse side of the board and continue drilling all the way through pool.
This will eliminate wood splinters.

1. Take one of the 12” x 28” panels and
lay out as per “Front Panel - Cut
Schedule B”
2. For all the areas marked cut out drill 1
or 2 holes as starting point for the
jigsaw blade. (See photos)
3. The eleven cut-outs will be for the
discs to peer through. (1 x 1 1/2)
4. One cut-out will be for the simulated
(3) fuel selection switches (3 1/2 x 6)
5. The last cut-out is for the Credit Card
slot (1/2 x 1 1/2)
6. A 7/16” spade bit is used to drill the
starting holes for the jigsaw. (See
photos)
7. Use the jigsaw with a smooth cutting
blade to make the cuts for the holes.
Look at photos for further detail…
8. You will have a total of 13 cut-outs
when completed.
9. Use the orbital sander with a 220 grit
disc to sand the front panel.
10. Upon completion of sanding, use (my
choice) Red enamel paint. I put on
two coats using a 2” sponge brush.

1. The credit card assembly will be glued
onto the back of the front panel of the
Gas Pump.
2. From the 1/2” plywood scrap cut to
sizes on the cut schedule “C” for the
credit card. Also use photos as a
guide.
3. Use CA wood glue to assemble the
box.
4. After the box is assembled and dry,
align it behind the front panel slot.
5. Glue the box, using CA glue onto the
back of the front panel.
6. Install the 3-gang electrical box, the 3
switches, and the white cover plate.

1. In Step 1, eleven (11) 2” discs were
cut using a hole saw.
2. Use sandpaper to smooth the outside
diameter surface.
3. Use a 1/4” drill bit to clean the
center hole of the disc.
DO NOT OVERSIZE THIS HOLE.
4. Once the discs are smooth, it is time
to paint them. I placed a dowel
through the center, spacing the discs
a few inches apart and the spray
painted them gloss black. I then
suspended the dowel using a
cardboard box. Allow to dry
completely.
5. Using a label maker, make eleven(11)
strips of numbers (0,,2,3,4,5,6,7,8,9)
(see photo.) white numbers on clear.
6. Make sure the numbers are printed
vertically.
7. Attach each strip of numbers onto the
dry disc. (See photo) 11 Total discs.
8. DIAL HOLD-DOWN BRACKETS
SCHEDULE “C”
a. Take two pieces of 2” x 6 3/4” of
wood and tape them together.
b. Mark locations to be drilled as
indicated on drawing.
c. Using a 5/16” wood drill bit, drill all
the way through.
d. Repeat steps 8a - 8c for second
set of hold-down brackets.

There are three (3) wheel/disc assemblies which have to be put together.
For this step you need:
1/4” wood dowel
1/4” inside diameter clear rubber tubing
11 (eleven) - black and numbered
wheels/discs.
CA GLUE

1. The objective of this step is to place
spacers (1/4” tubing) between the
wheels so that they are aligned with
the slots in the front panel without
moving side to side and still rotate
freely.
2. Follow the dimensions on the drawing
as well as the photos. It’s a little
tricky so don’t give up. It’s worth the
time spent to do this right. The
dimensions may need to be adjusted
depending on the slots cut into the
front panel.
3. It may be a good idea to put a dab of
CA glue to hold the tubes from
shifting.
⚠️ CAUTION ⚠️
DO NOT GLUE THE WHEELS!
⚠️ ⚠️ ⚠️
4. Repeat Step 2 and 3 for the
remainder two shafts.
5. Remember which set of wheels go
when you proceed to STEP 6.

1. Glue down the 2” wood strip as
shown in photo and drawing.
Do this on both sides of
the underside of the front panel.
Spread glue under the strips.
2. Line up the 1/4” dowels with the
wheels assembly from STEP 5 into
the slots so that the discs(wheels)
rotate freely in the front panel slots.
3. Repeat #2 for all 3 rows of wheels.
4. Adjust the spacers between the
wheels as needed to maintain free
rotation of each individual wheel.
5. Place and align the top 2” x 6”
section over the dowels. Make sure
wheels rotate freely. The dowels
should not rotate.
DO NOT GLUE THE TOP PIECE
6. Drill and countersink six (6) holes as
indicated on drawing.
7. Use #6 - 1” wood screws to secure
the top piece.
8. Check again to make sure each wheel
rotates freely.
9. Screw the top piece to hold the dowel
down.

1. Assemble the front, back, top and
bottom. Use a square corner clamp to
make assembly a bit easier.
2. Assemble the sides of the Gas Pump.
3. Assembly requires the use of #6 - 1”
wood screws. Drill and countersink all
screws.

1. For the Fuel Nozzle I used a spray
bottle nozzle.
2. Clean the nozzle from any chemicals.
3. Using 3/8” x 24” clear rubber tubing, I
slid one end over the tube and into the
bottom of the nozzle, then used CA
glue to permanently attach together.
4. For the other end, mount a
1/4 -20 x 1” through the right side of
the Gas Pump approximately 20”
from the floor.
5. Dab some CA glue onto to bolt and
into the end of the 3/8” tube. Slide
the tube over the bolt and allow to
dry.
6. Take a piece of wood 6” x 3” to make
the nozzle holder. Schedule “C”
7. Cut out a 2” hole and round off the
corners as in drawing and photos.
8. Attach the nozzle holder using 2
#8-1 1/2” wood screws.
9. The spray nozzle can now be inserted
onto the side of the gas pump.

1. Use the orbital sander with 220 grit
sanding discs to go over all the flat
surfaces.
DO NOT SAND THE FRONT (RED)
2. Paint the rear of the Gas Pump Gloss
Blue. The side are Gloss White. Top
is Red.

PAINT MUST BE THOROUGHLY DRY
PRIOR TO PLACING THE LABEL ON.

3. Use the label maker with white letters
and clear background tape to make
all the labels for the front of the Gas
Pump.
4. Labels to be made are:
GALLONS DELIVERED, COST PER GALLON, AMOUNT OF SALE, TAX INCLUDED, $, $, NO SMOKING, INSERT CARD, REGULAR, PREMIUM, PLUS, 87, 89, 91, PAY CASH INSIDE,
GAS STATION OWNER ….(your name).

5. Look up your favorite Gas Station
name and print out two logos. I
placed (glued) one on top and one on
bottom of front panel.

This is it. The final step!
1. It’s time to put on the decals and
Logos. You can use my suggestions
or create your own.
2. If some decals do not stick then you
can use a clear glue under them.
3. For another final touch, I got an old
McDonalds card and attached yarn to
it. The other end of the yarn is
fastened under the 3 switch cover
plate.
4. I also added an old solar calculator to
the front panel. The child can get
used to a calculator.
5. Currently no electrical is hooked up to
the Gas Pump. In the future I will
hook up the 3 gas select switches to
3 lights.
I wanted this Pump to be moveable
from one spot to another so no
wire/electrical connection.
6. Lastly I placed two (2) “D” hooks on
the back of the Gas Pump so that it
can be attached to the wall for safety.

On completion I took this to my Grandson. After watching my Grandson play with this, I choked a bit. Realizing that my work may become a family heirloom.
I hope you all enjoy this build as much as I do.