How to Build a Cart From PVC

A PVC kayak cart is a quick and easy way to carry a kayak down to the water line for safe deployment. Dragging a kayak without a cart can result in damage to the bottom of the kayak, ultimately leading to leaks. Additionally, by using a rolling cart to support the back half of the kayak, you make the load much easier to carry, particularly when you're dealing with difficult terrain such as sand or rocky shores.

Things You'll Need

  • 7 PVC end caps
  • Power drill
  • Drill bit, 1/2-inch diameter
  • 2 PVC pipes, 12 inches long
  • PVC pipe, 16 inches long
  • 4 PVC pipes, 2 inches long
  • 4 PVC T-sockets
  • 4 PVC pipes, 9 inches long
  • PVC glue
  • Metal pipe, 1/2-inch diameter
  • 4 nylon spacers
  • 4 metal spacers
  • 2 wheels
  • Hacksaw
  • 2 hitch pins
  • PVC pipe, 28 inches long
  • PVC coupler
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Instructions

    • 1

      Drill a 1/2-inch-diameter hole in the center of two PVC end caps.

    • 2

      Insert a 12-inch pipe into the bottom opening of a T-socket, and a 2-inch pipe into one of the two top openings of the socket. Repeat with a second T-socket, 2-inch pipe and 12-inch pipe.

    • 3

      Connect the two assemblies together with a single 16-inch pipe using the remaining opening on each T-socket.

    • 4

      Place an end cap on each open end of the 2-inch pipes on the assembly.

    • 5

      Insert a 9-inch pipe into both top openings of a T-socket, then repeat for a second socket.

    • 6

      Place the T-socket with the 9-inch pipes atop the remaining open end of the 12-inch pipes on the assembly. Turn the sockets with the 9-inch pipes so they run parallel to each other, perpendicular to the 16-inch bar in the assembly.

    • 7

      Drill through the bottom extension of both T-sockets attached to the 9-inch pipes with a 1/2-inch-diameter bit, approximately 3/4 inch from the end of the opening. Drill through one side of the socket being drilled, through the 12-inch pipe that is in the socket and out the other side of the socket.

    • 8

      Remove a 12-inch pipe from a drilled T-socket and file around the perimeter of the pipe on the side the hole is drilled, filing approximately the last 1 1/2 inches of the pipe. This decreases the size of the pipe to make it easier to slide in or out when not pinned. Repeat for the second drilled pipe.

    • 9

      Secure the PVC pipes in the assembly in place with PVC glue in every joint except where the drilled pipes slide into the drilled socket. Be sure to maintain the same orientation of the 12-inch pipes when you glue them so that the holes will align with the holes in the sockets properly.

    • 10

      Insert the drilled ends of pipe back into the drilled couplings, so the holes align.

    • 11

      Pass the pipe through one end cap, across the bottom of the assembly and out the other end cap.

    • 12

      Thread a nylon spacer and two steel spacers onto each end of the pipe.

    • 13

      Put a wheel on each end of the pipe, so the steel spacers sit inside the wheel.

    • 14

      Thread another nylon spacer on each end of the pipe.

    • 15

      Slide the pipe so it extends 3/4 inch beyond the last spacer on one end, then measure 3/4 inch from the last spacer on the other end of the pipe and mark the pipe. Remove the pipe and cut it along the marked point.

    • 16

      Drill a hole with a 9/64-inch bit, 5/8 inch from one end of the pipe, then again 5/8 inch from the other end of the pipe. Both uses of the drill should pass all the way through the pipe, making a total of four holes.

    • 17

      Slide the pipe back through the assembly and secure the wheels and spacers, then slide a hitch pin through each drilled hole to secure the wheels to the axle.

    • 18

      Insert a 28-inch pipe into the bottom opening of a T-socket, and 2-inch pipes into each top opening. Cap the 2-inch pipes with end caps. Secure all the parts with glue.

    • 19

      Attach the 28-inch pipe's open end to the coupler, then secure the second end of the coupler to one of the 9-inch pipes on the main assembly. Cap the remaining three 9-inch assemblies.

    • 20

      Tie a knot in one end of the 3/8-inch cord.

    • 21

      Pass the loose end of the cord through one drilled T-socket and pipe, starting on the outside of the assembly so the loose end hangs between the two uprights of the assembly. Pass the loose end through the second set of drilled pieces as well, so the end hangs on the outside of the assembly.

    • 22

      Tie a knot in the loose end, snug against the outside of the second T-socket. The rope will help prevent the cart from breaking and the support arms spreading to the side.