Tired of struggling to move your kayak from your garage to the water? Building a DIY kayak storage rack and launch cart can save you backache and money in the long run. I’m Robert Kline, and with years of experience in crafting and DIY projects, I’m here to guide you through the process of building a cart that’s strong, lightweight, and customized for your kayak.
This project is a step up from basic PVC carts, offering a level of sturdiness that rivals commercially available options. While it involves a few more steps and materials, the satisfaction of building it yourself and the longevity of the final product make it a rewarding endeavor.
Gathering Your Materials
Here’s a comprehensive list of the components you’ll need for your DIY kayak storage rack and launch cart. I’ve included links to readily available materials to make your sourcing easier:
Main Components:
- SuperStrut Metal Framing Channel: You’ll need about 15.5″ per cart. It’s available at most hardware stores, like Home Depot.
- Steel Axle: A 3/4″ x 1/16″ plain steel tube, cut to 25.5″, will do the trick. You’ll need to drill holes in each end for linch pins. Again, Home Depot is a good source for this.
- Cutting Board: A dense polyethylene cutting board, about 1/2″ thick, will form the bunks for your kayak to rest on. You’ll need two 3″ x 15″ sections per cart.
- Wheels: I recommend 10″ low-speed tires for their durability and smooth rolling.
- Brackets and Fasteners: You’ll need Superstrut 2-hole 90-degree angle brackets, Crown Bolt Inc. 1/2″ Create-A-Bolt, Crown Bolt Zinc Plated 1/2″ – 13 x 1-3/4″ Rod Coupling Nuts, Crown Bolt 3/16″ x 1-1/2″ Zinc Plated Linch Pins, Crown Bolt Zinc Plated 1/2″ – 13 x 1-1/2″ bolts, Crown Bolt Zinc Plated 5/8″ Flat Washers, 1/2″ Flat Washers, Crown Bolt 1/2″ x 12″ Zinc Threaded Rod, 1/2″ stop nuts.
Additional Items:
- PVC Piping: You’ll need 1/2″ PVC couplings and 3″ sections of 1/2″ PVC pipe.
- Padding: Outdoor carpet scraps or foam padding will protect your kayak’s hull.
- Lashing Strap: This will secure the cart to your kayak during transport.
- Optional Extras: Foam tubing for the PVC arms, a U bolt and 1/2″ PVC parts to fabricate a push pole holder, and automotive truck bed coating for added durability.
Expert Tip from Sarah D., DIY enthusiast: “Sourcing your materials in bulk, especially if you’re building multiple carts, can save you money. Check online retailers or consider teaming up with other kayaking enthusiasts for a group purchase.”
The Build: Step-by-Step
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Creating the Frame: Start by cutting the SuperStrut to 15.5″ sections. Then, attach the 90-degree angle brackets to the SuperStrut using the Create-A-Bolt fasteners.
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Assembling the Axle: Drill holes in the ends of your steel axle to accommodate the linch pins. Slide a flat washer, followed by a wheel, onto each end of the axle. Secure the wheels with another set of flat washers and linch pins.
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Building the Bunks: Cut the cutting board into 3″ x 15″ sections. These are the bunks that your kayak will rest on. Cover the bunks with outdoor carpeting or foam padding to prevent scratches.
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Attaching the Bunks to the Frame: Position the bunks on the SuperStrut frame, ensuring they are evenly spaced and provide adequate support for your kayak. Secure them to the frame using the remaining bolts, washers, and nuts.
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Adding the PVC Arms: Cut the 1/2″ PVC pipe into 3″ sections. These will act as vertical supports for the arms that connect the frame to the axle. Attach a PVC coupling to each end of the 3″ PVC sections.
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Connecting the Axle to the Frame: Insert the threaded rod through the PVC couplings and the holes in the SuperStrut frame. Secure the rod with nuts on both sides. Slide the axle assembly onto the threaded rod, ensuring that the wheels are positioned outside the frame. Secure the axle to the threaded rod with nuts.
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Finishing Touches: Apply truck bed coating to the frame and axle for added durability and a professional look.
Conclusion
Building your own DIY kayak storage rack and launch cart is a project that pays dividends in satisfaction and functionality. Not only will you have a sturdy and reliable cart, but you’ll also have the pride of creating something with your own hands. With a little time, effort, and the right materials, you can easily build a cart that meets your specific needs and budget.
Ready to take your crafting journey further? Explore more unique handmade gift ideas and DIY projects on our website, [Robert Kline Art](your website address). Share your kayak cart creations and connect with our vibrant crafting community in the comments below!