By Wood-Mizer, USA
December 17, 2025
In this episode of The Wood Life Podcast, host Duston Moore visits Ken Postema, the driving force behind a remarkable wooden car project that has grown from a humble hobby into a nationwide movement crafting thousands of toy cars for Operation Christmas Child—and changing lives in the process.
What do you get when you combine woodworking skills, a passion for giving, and some seriously creative problem-solving? Nearly 100,000 wooden toy cars delivered to children in need around the world—in a single year. Ken Postema's journey started with a simple question: could he create something meaningful for kids receiving Operation Christmas Child shoeboxes? The answer transformed his garage into a production hub that now involves volunteers from church groups to assisted living facilities, including his 95-year-old father who assembled over 11,500 cars in one season.
We explore how Ken scaled from 10,300 cars in year one to 96,420 today, the ingenious tools he's built (including a repurposed cement mixer for sanding and custom drill jigs using salvaged cordless drill motors), and why he's eager to share his entire process so others can replicate it. From cost management strategies that cut expenses by 25% to volunteer networks spanning the country, Ken's story is a masterclass in turning craft into measurable, global impact. Whether you're a woodworker looking for purpose-driven projects or someone inspired to start your own charitable initiative, this conversation offers both inspiration and a practical blueprint.
Key Takeaways:
1. Purpose-Driven Craft Creates Powerful Impact: Each wooden car represents more than a toy—it's often a child's first-ever gift, making the story behind the materials and the mission critical to motivating volunteers and maintaining high standards.
2. Scale Through Smart Systems: Ken grew from 10,300 to 96,420 cars annually by designing scalable processes, partnering with lumberyards for donated materials, and distributing pre-packaged car kits to volunteers nationwide.
3. Creative Tools Drive Efficiency: From a Wood-Mizer moulder planer with custom knives to a repurposed cement mixer for batch sanding to custom drill jigs using salvaged motors, Ken's innovations turned labor-intensive work into efficient production.
4. Make Volunteering Accessible to Everyone: Pre-packaged car kits allow volunteers of all ages and abilities to participate—from children to seniors, including a 95-year-old who assembled 11,500 cars and volunteers with Alzheimer's who find joy in the hands-on work.
5. Cost Management Enables Sustainability: Transitioning to donated lumber, investing in a custom die that reduced per-car costs by 25%, and bulk purchasing made the project financially sustainable even at massive scale.
6. Share Your Process to Multiply Impact: Ken openly shares his methods and invites others to replicate his project, proving that the best way to scale charitable work is by empowering others to start their own initiatives.
7. The Ripple Effect Goes Beyond Recipients: These cars provide first-ever gifts for children worldwide, create meaningful engagement for volunteers with cognitive challenges or limited mobility, and build community through shared purpose—proving craft can heal and connect at every level.
If you're inspired by Ken's story, share it with your church, community group, or maker friends, leave a review, and subscribe for more stories from the Wood Life Podcast.
"For many children, this wooden car is their first-ever gift—a tangible reminder that someone, somewhere, cares."
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