An unusual commission came into the workshop: a request to build a large, bespoke wooden toy train to hold gifts at a baby shower. The client wanted something special, practical and completely unique.
Mike designed and built the entire train from scratch. As a result, every part could be made specifically for this one-off commission, from the carriage frames and 22 individual wheels to the engine boiler and personalised lettering.
Building the Carriages
First, Mike set out the frame‑and‑panel construction for the carriages, using mainly hemlock and birch plywood throughout the build. With the materials prepared, he began cutting the mortise and tenon joints for the carriage frames. Each frame was then shaped with a groove to receive its panel, ensuring a clean and accurate fit. To reinforce the joinery, Mike added a haunch to every tenon — a thoughtful detail that blocks the groove and provides extra surface area for gluing.
Once the joinery was complete, he assembled the panels to form the individual carriage boxes. After the boxes were built, he fitted the three rear carriages with tall wooden handles, allowing each one to be lifted and carried independently: a practical finishing touch that complements the handcrafted design.
Making 22 Wooden Wheels
Next came the wheels. Mike began by marking out all twenty two wheels on 18 mm birch plywood before cutting each one to shape. Once they were roughed out, he turned his attention to consistency — every wheel needed to be identical for the train to run smoothly and look balanced.
To achieve that precision, Mike built a custom sanding jig, which allowed him to shape each wheel accurately and repeatably. With the profiles established, he moved to the router table to radius the edges, giving every wheel a clean, finished contour. After that, he sanded each one by hand, preparing them for the final finish.
Twenty two wheels later, the train was truly beginning to take shape.
Constructing the Engine
The engine presented a different challenge. Mike needed to create a cylindrical boiler, but the process had to begin with an octagon. Because of this, he spent time experimenting with different construction methods and dimensions before settling on the final design. Once he was satisfied, he assembled the octagonal form and prepared it for the wood lathe.
With the blank ready, Mike turned the octagon down into a true cylinder. After achieving the final shape, he refined it further by shaping and sanding the boiler before fitting the end caps. To strengthen the structure, he added reinforcing splines — a small detail that, surprisingly, worked extremely well.
Fitting the Train Base and Axles
Later, the train base was prepared to receive the boiler and cab. Mike made the axles from 8mm threaded bar and secured them into timber using epoxy resin.
Next, he shaped and fitted the remaining components. He also made the brackets needed to connect the individual carriages to the engine.
At this stage, the separate components were beginning to come together as one complete wooden train.
Laser-Cut Lettering
To make the train personal to the new arrival, Mike created laser-cut lettering for the engine and carriages.
The finished engine carries the name “NOAH”, adding a personal touch to this bespoke wooden toy train and making it a truly individual baby shower gift.
Finishing the Bespoke Wooden Toy Train
Before the final assembly, Mike sprayed the individual components and assemblies with lacquer. This gave the wood a durable finish while allowing its natural character to remain visible.
Finally, he made a cord and hand-turned wooden ball to attach to the front of the engine. This provides the handle for pulling the finished train along.
A One-Off Wooden Baby Shower Gift
The finished train is a completely bespoke wooden toy, designed and handmade from scratch in Mike’s workshop. From the carefully constructed carriage frames to the 22 individually finished wheels, every element had to be designed, shaped, and fitted by hand. The turned wooden boiler, personalised lettering, and pull cord bring the whole piece together, creating a unique toy made especially for a very special baby shower.
Altogether, it stands as a great example of the kind of bespoke woodworking project we can take from an initial idea right through to a finished piece, with every detail shaped around the customer’s requirements.
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