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Step 2Cart Fabrication overview
Fabrication Breakdown(more detail in next steps)
Get 5 pieces of 1/2" EMT conduit and cut and bend in the following manner:
Piece #1:
Full length. Mark and bend at 2", 41", 61", and 100". Overlap the last 2".
Piece #2:
Cut at 59". bend 6 1/2" from each end to make a "U" (spine)
Cut at 38 1/2". bend 5 3/4" from each end to make a "U" (rib 1)
Piece #3:
Cut at 38 1/2". bend 5 3/4" from each end to make a "U" (rib 2)
Cut at 38 1/2". bend at 3/4" from each end to make a "U" (wheel well 1)
Cut at 38 1/2". bend at 3/4" from each end to make a "U" (wheel well 2)
Piece #4:
Cut at 50" and bend a 45 degree bend 10" from end (bottom pulling arm)
Cut at 51", and bend a 45 degree bend 11" from end (top pulling arm)
Cut a 15" piece (arm brace)
Piece #5:
Cut a 72" piece. Bend at 26" from each end to make a "U" (handle)
From flat stock: (1" by 3/16" thick): make (4) 1 1/2" long dropouts with a 3/8" slot.
*Miter the ends of the tubes with a file to fit as shown in the assembly diagram.
*Braze the main-frame, ribs, and spine together.
*Make a dropout jig. each set of dropouts is 4" apart, and space the sets at 22 1/2".
*Put the dropouts in the jig and support the jig level from the ground so that the wheel wells rest on the outside dropouts, and the inside dropouts contact the center rib. Braze.
*Braze the two pulling arm pieces together as shown in the assembly diagram.
*Braze the pulling arm to the front and center ribs. Add the arm-brace.
*Drill a hole in the pulling arm at the end, and attach a 2" long 3/8" bolt as shown.
*Make a hitch out of 1" by 3/16" flat stock, 1/4" rod, and a 3/8" ID tube as shown.
*Make an extended wing nut, attach 2 front bicycle wheels to the cart, paint the joints.
*Add a plywood bed made that is 19" by 38" with notches cut for the ribs and spine.
Get 5 pieces of 1/2" EMT conduit and cut and bend in the following manner:
Piece #1:
Full length. Mark and bend at 2", 41", 61", and 100". Overlap the last 2".
Piece #2:
Cut at 59". bend 6 1/2" from each end to make a "U" (spine)
Cut at 38 1/2". bend 5 3/4" from each end to make a "U" (rib 1)
Piece #3:
Cut at 38 1/2". bend 5 3/4" from each end to make a "U" (rib 2)
Cut at 38 1/2". bend at 3/4" from each end to make a "U" (wheel well 1)
Cut at 38 1/2". bend at 3/4" from each end to make a "U" (wheel well 2)
Piece #4:
Cut at 50" and bend a 45 degree bend 10" from end (bottom pulling arm)
Cut at 51", and bend a 45 degree bend 11" from end (top pulling arm)
Cut a 15" piece (arm brace)
Piece #5:
Cut a 72" piece. Bend at 26" from each end to make a "U" (handle)
From flat stock: (1" by 3/16" thick): make (4) 1 1/2" long dropouts with a 3/8" slot.
*Miter the ends of the tubes with a file to fit as shown in the assembly diagram.
*Braze the main-frame, ribs, and spine together.
*Make a dropout jig. each set of dropouts is 4" apart, and space the sets at 22 1/2".
*Put the dropouts in the jig and support the jig level from the ground so that the wheel wells rest on the outside dropouts, and the inside dropouts contact the center rib. Braze.
*Braze the two pulling arm pieces together as shown in the assembly diagram.
*Braze the pulling arm to the front and center ribs. Add the arm-brace.
*Drill a hole in the pulling arm at the end, and attach a 2" long 3/8" bolt as shown.
*Make a hitch out of 1" by 3/16" flat stock, 1/4" rod, and a 3/8" ID tube as shown.
*Make an extended wing nut, attach 2 front bicycle wheels to the cart, paint the joints.
*Add a plywood bed made that is 19" by 38" with notches cut for the ribs and spine.
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