How to Assemble a Milk Crate Kayak Cart

Kayak carts are used to aid in the transport of kayaks from storage to vehicle or from vehicle to water put-in points. Carts allow for kayaks, especially longer open-water and sea models, to be moved by a single person. There are several commercially made carts available, however, it is possible to construct a cart using an empty plastic milk crate and some easily-obtained parts.

Things You'll Need

  • Empty plastic milk crate
  • Drill
  • Drill bit (3/4" and 1/8")
  • Saw (capable of cutting plastic)
  • Self stick foam pipe wrap
  • 1/2 " metal rod
  • 1" PVC end caps (2)
  • 1/2" fender washers
  • Cotter pins
  • Pneumatic tires (2)
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Instructions

    • 1

      Drill a 3/4 inch hole in the lower rim of the milk crate. The hole should be drilled so that it is centered on the crate. There will typically be a wide support strip of plastic along the lower edge of the milk crate. Repeat the process on the opposite side, making sure the holes line up directly across from one another.

    • 2

      Drill a 3/4" hole in the center of both PVC end caps. Center the holes in the caps as these will serve as spacers on either side of the crate for the wheels.

    • 3

      Drill a 1/8 inch hole at each end of the metal rod. The rod should be long enough to pass through the milk crate and accommodate the PVC end caps, wheels, washers and extend about 1/2 inch outward from the wheel to allow a retaining clip to be inserted.

    • 4

      Slide the metal rod through the milk crate so that it is centered with equal lengths extending from both sides. Slip a PVC cap over both ends with the open end toward the crate. Next, slide a fender washer on both ends and then the pneumatic wheels. Finally, slide a second fender washer on the outside of the wheels and secure both ends by clipping a retaining clip through the holes in the metal rod.

    • 5

      Use a saw capable to remove the plastic section above the hand holds of the milk crate. Attempt to make the cuts in a"V" shape down to the hand hold cut-outs.

    • 6

      Apply foam pipe wrap to the top edges of the milk crate by removing the adhesive protection strip and firmly pressing the foam wrap along the edge. Make sure to work the foam wrap down into the "V" cut-out.