Scratch building some supply carts

I plan to set up a small campaign for the French and Indian War (FIW) in the near future. As I don't have any supply carts, I decided to scratch-build some for my armies. I used to have some spare plastic cart wheels stored away, but over time they became brittle. I considered buying replacements, but they would take time to arrive, so I chose to make my own by making a mould from one of the broken wheels. Nothing fancy, just something basic that resembles a wheel on one side and can be attached to scrap wood shaped to look like carts. I used a polymer clay to make the wheels which stays flexible until baked in the oven to harden, after which it can be sanded and painted.

A completed supply cart.

To create the wheels, I began by making a simple mould using Milliput epoxy putty. I pressed the broken wheel into the putty to form the shape. Since the putty takes overnight to set, I had plenty of time to widen the spokes, make gaps for the missing ones, and make sure everything looked ok.

A mould is made from Milliput using a broken wheel.

The next steps involved pressing the polymer clay into the hardened mould and cleaning up the wheel ready for baking.

1. Lightly dusted the mould with talcum powder.  
2. Soften the clay by working it until it becomes malleable, then pressed it into the mould.  
3. Carefully removed the clay from the mould.  
4. Trimmed off any excess around the edges.  
5. Straighten the spokes and ensure the wheel is circular (as it does become slightly misshapen during removal from the mould).
6. Baked the clay in the oven to harden.  
7. Once hardened, the wheel is sanded for a smooth finish.  

I chose polymer clay over epoxy putty because it's easier to handle and doesn't stick to surfaces as much.

The polymer clay is pressed into the mould.

The clay comes out of the mould slightly misshaped, but this is sorted out later.

The excess clay is trimmed off.

Spokes are straighten and the wheel made circular with modelling tools. 

After baking, the set wheels are sanded.

The cart is made from a piece of wood sawed into shape, with additional items like a canopy or a variety of bits added to represent barrels and crates. The horse an unused cavalry horse from a kit, with its saddle filed off and a collar made from Green Stuff.

Bits of balsa and beads are added for the stores.

A horse and handler are prepared.

While the painting is very simple, I do paint on a few highlights, especially the spokes. A final coat of gloss hides the many imperfections. 

Now the carts are made. I plan to make a ship and some boats for some amphibious scenarios.

The carts can be used by either army.