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What this wooden cargo scooter is—and what “hundreds of pounds” means
A chukudu is a large wooden cargo scooter. In a 2015 project article, Doug Bradbury describes how chukudus were used to move food and firewood rations in Kiziba refugee camp, and adapts a design explained by chukudu designer Aimé Nshimiyimana. Make: attributes the design drawings to Nshimiyimana and the build account to Bradbury.
The article says traditional chukudus carry “upwards of 500 pounds.” It does not report a load test of this particular adaptation, define whether the figure means payload or total load, or establish a safe limit under movement, impact or downhill braking. Do not use 500 pounds as a design rating for a new build.
Plan and materials
The project’s main structure is a five-foot 2×10 deck, a laminated fork made from three 12-inch 2×10 pieces, a two-inch hardwood dowel steering shaft and a four-foot 2×4 steering support. The design uses two steel wheelbarrow or cart wheels, 5/8-inch threaded rod for axle pieces, nylon lock nuts, rubber tie-down straps for suspension, and salvaged bicycle tire and inner tube for the brake and connections.
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- Amish Scooter; Made in Lancaster County, Pennsylvania by Amish Craftsmen.
- Features Aluminum-Rimmed Racing Wheels; 24" Front Wheel and 20" Back Wheel.
- Adult Size Scooter; Same Model That The Amish Use in Lancaster County, PA.
- Comes Standard with Handy Cargo Basket and Front and Rear Brakes.
- Genuine Amish-Built Quality; Built to Last a Lifetime of Scooting.
- Wood and joining: dimensional lumber, hardwood dowel, wood glue, nails and staples.
- Running gear: two steel cart wheels, threaded rod, lock washers and nylon lock nuts.
- Flexible parts: four rubber tie-down straps, salvaged bicycle tire and inner tube.
- Tools: jigsaw, handsaw, hammer, 1-inch chisel, 2-inch hole saw, drill and bits, hacksaw or reciprocating saw with metal blade, wrench, sandpaper and clamps or weights. An optional router with ¾-inch straight-cut and roundover bits helps shape the work.
Before committing to those dimensions, verify that the wheel diameter, axle length, bearing arrangement and fork/deck clearances work together. The source names no wheel model or component load rating; check the actual parts and their manufacturers’ specifications for the intended use.
Build the deck
- Cut a 2×10 to five feet long. Round the nose, using a 10-inch wheel as the shaping template.
- Make a two-inch opening for the steering shaft and an 8×3-inch notch at the rear for the wheel and brake area.
- Optionally cut a ¾-inch-wide, ¼-inch-deep groove to help retain the rear axle.
Keep the openings and notches cleanly fitted, but do not assume that matching the dimensions alone proves the deck or its joints can carry a particular load.
Rank #2
- DURABLE WOOD CONSTRUCTION – Built from heavy wood for long-lasting strength and stability during active play
- FULL PERIMETER BUMPER – Protects walls, floors, and other scooters from damage during group activities
- NON-MARRING SWIVEL CASTERS – Smooth-rolling plastic wheels glide easily without scuffing gym floors
- HANDLE-FREE DESIGN – Allows a full range of motion for seated, kneeling, or prone movement exercises
- 2-INCH SIZE – Measures 12" x 12" with a weight limit of 175 lbs, ideal for physical education and recreational use
Laminate the fork and fit the steering shaft
- Cut three 12-inch lengths from 2×10 stock. Bevel the two outer pieces, groove the center piece for the axle, and notch all three pieces as shown in the project design.
- Shape both ends of a two-inch hardwood dowel to meet the fork and handlebar connections.
- Glue and clamp the three fork pieces around the dowel, keeping the parts aligned while the glue cures.
Inspect the laminated assembly for gaps, splits, misalignment and movement before fitting the wheels or riding it. The project article does not give a structural test result or a safe load value for this joint.
Install the steering support and handlebars
- Fit a four-foot 2×4 steering support into a 3½×1⅞-inch opening in the deck, angled at 20 degrees.
- Shape its upper end to meet the steering shaft. The project places this contact point 6–8 inches from the top of the shaft.
- Shape a 30-inch 2×4 into handlebars, leaving a six-inch center hub and two handles. Cut a snug opening for the shaft and round sharp edges.
- Wrap the steering-support connection with salvaged bicycle tire. Attach the handlebars using inner tube, a shim or a wedge, as appropriate to achieve a secure fit.
Check that the steering turns freely without looseness, binding or visible flex at the connections. A fit that seems tight while stationary is not, by itself, evidence of control under a heavy moving load.
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- Vintage-inspired rubber grips
- Weight: 7.4 lbs (including basket)
- Wide oak scooter deck with anti-slip tape
- Scooter deck dimensions: 17.7 x 4.5 inches
- Classic steering system, just like a bike
Fit the wheels and axles
- Cut 5/8-inch threaded rod into two eight-inch axle pieces.
- Center a steel wheel on each axle and secure it with nylon lock nuts. Use compatible washers and hardware for the wheel and bearing arrangement.
- Secure the axle assemblies at the deck and fork, preventing lateral movement while allowing the wheels to turn freely.
Confirm that the wheel, axle, nuts, washers and supporting wood are compatible as a system. The Make: plan specifies steel cart or wheelbarrow wheels, but it does not establish the capacity of any wheel, axle or bearing, nor rate the assembly as a whole.
Add suspension and the rear friction brake
- Nail rubber tie-down straps around the deck nose and attach them to the steering shaft.
- Adjust the straps so the deck sits 6–8 inches above the fork.
- Fix a seven-inch section of bicycle tire into the rear-wheel notch. The rider operates it by stepping back to press the tire against the rear wheel.
The tire is a simple friction brake intended to slow the scooter; the project reports no stopping-distance or brake-performance test. Do not assume it can safely stop a heavily loaded scooter, particularly on a slope or loose surface.
Rank #4
- DURABLE WOOD CONSTRUCTION – Built from heavy wood for long-lasting strength and stability during active play
- FULL PERIMETER BUMPER – Protects walls, floors, and other scooters from damage during group activities
- NON-MARRING SWIVEL CASTERS – Smooth-rolling plastic wheels glide easily without scuffing gym floors
- HANDLE-FREE DESIGN – Allows a full range of motion for seated, kneeling, or prone movement exercises
- 16-INCH SIZE – Measures 16" x 16" with a weight limit of 175 lbs, ideal for physical education and recreational use
Check the build before carrying cargo
The project article supplies construction details, not an engineering certification. Before use, examine the deck, fork laminations, steering connections, axle mounts, wheel fasteners, straps and brake for looseness, damage or wear. Consider these questions when deciding whether the design suits a particular job:
- Do the wheel diameter, fork geometry and deck clearance allow the wheels to rotate without rubbing or binding?
- Are the wheels, axles, bearings, fasteners and timber supports rated for the intended load and use?
- How will cargo be restrained so it cannot shift into the steering or wheel area?
- Can the rider steer and slow the vehicle on the actual route and terrain?
- Can you inspect and maintain the joints, straps and fasteners regularly?
Make: warns that the scooter’s size and mass can make it difficult to handle, and advises wearing a helmet and having an escape plan. Start without cargo in a clear area and do not carry a load until steering and braking are controllable; avoid treating a successful slow roll as proof of performance under heavier or faster conditions.
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- 【360 Degree Rotating Wheels】--- Our safety scooters adopt 360 degree rotating wheels instead of one direction wheels, allowing for easy multi-direction movements.
- 【Indoor/Outdoor Activity】--- Our gym floor scooter is very suitable for the gym class, blacktop, basement or any flat hard floor surface.
- 【Physical Exercise】--- The sitting scooter board activity could provide sufficient movement and great exercise, which help youngsters develop core strength in both the upper and lower body while having fun.
- 【Sturdy & Durable】--- The gym scooters board for kids is made of durable wood, can hold up to 135lbs. The dimension of it is 11.8" x 11.8" x 2.95”.
- 【Protective Handles】--- Handles on both sides of the sitting scooters provide easy steering and control, ensuring that children's hands are protected from the rollers.
Time and cost in the original project
Bradbury’s 2015 Make: article estimated about a weekend to build and $100–$200 depending on supplies already available and salvaged materials. That is a historical estimate, not a current materials budget; lumber, hardware and tool costs vary by location and date.
Project source
The construction outline and historical estimates above are from Doug Bradbury, “Build a Burly Wooden Scooter That Can Haul Hundreds of Pounds,” Make:, originally dated July 28, 2015; the page also displays July 15, 2022. The article credits Aimé Nshimiyimana with the component and assembly drawings.
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