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Step 4Constructing the Cage/Basket
For the cage or basket around the cart, I used PVC conduit.
There are 4 vertical posts which also act as rod holders, made out of 1 1/2" ID pvc conduit.
The rail members are all 1" pvc conduit. These are straight lengths and prefabricated radiused corners. The radius sections have a flared flange one end, which receives the straight sections. Where no flare is provided, the conduit sections are connected with couplers. Fixed connections are bonded with pvc glue.
The 1" conduit side rails were coped with a bandsaw to nest snugly around the outside of the 1 1/2" posts. The side rails were then bolted to the posts with machine screws and lock nuts. A larger hole was drilled on the outside of the post to allow the bolt head and screwdriver to fit through so that the inside face of the post is the only part bolted to the side rail. This allows the post to remain clear for rod handles and other vertical elements you will carry in these tubes.
The radiused sections are bonded to the side rails. In the end you should have two sides, each consisting of 2 posts and 3 rails (using 2 radiused sections per rail). Cut slots in the bottoms of the posts with a circular saw, bandsaw or jig saw, to fit over the upturned leg of the angle frame rail. Fit the two side assemblies over the frame rail angles to determine the length of the short pieces that will joint the two sides together. You will need 3 small straight sections each at the front and rear of the cage. These do not get bonded if you want to break down the cart for transport. These short pieces fit into the flared ends of the radius sections.
Drill holes through the posts, such that they also go through the upturned angle frame rail. The post will be connected to the frame with long machine screws and wing nuts. Because the posts are secured at the bottom, the short connecting pieces between the radius corners will only need to be secured at the top rails. This is done by screwing pan head screws through the flared end and into the short section.
There are 4 vertical posts which also act as rod holders, made out of 1 1/2" ID pvc conduit.
The rail members are all 1" pvc conduit. These are straight lengths and prefabricated radiused corners. The radius sections have a flared flange one end, which receives the straight sections. Where no flare is provided, the conduit sections are connected with couplers. Fixed connections are bonded with pvc glue.
The 1" conduit side rails were coped with a bandsaw to nest snugly around the outside of the 1 1/2" posts. The side rails were then bolted to the posts with machine screws and lock nuts. A larger hole was drilled on the outside of the post to allow the bolt head and screwdriver to fit through so that the inside face of the post is the only part bolted to the side rail. This allows the post to remain clear for rod handles and other vertical elements you will carry in these tubes.
The radiused sections are bonded to the side rails. In the end you should have two sides, each consisting of 2 posts and 3 rails (using 2 radiused sections per rail). Cut slots in the bottoms of the posts with a circular saw, bandsaw or jig saw, to fit over the upturned leg of the angle frame rail. Fit the two side assemblies over the frame rail angles to determine the length of the short pieces that will joint the two sides together. You will need 3 small straight sections each at the front and rear of the cage. These do not get bonded if you want to break down the cart for transport. These short pieces fit into the flared ends of the radius sections.
Drill holes through the posts, such that they also go through the upturned angle frame rail. The post will be connected to the frame with long machine screws and wing nuts. Because the posts are secured at the bottom, the short connecting pieces between the radius corners will only need to be secured at the top rails. This is done by screwing pan head screws through the flared end and into the short section.
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