How to Make a Luggage Cart

Build your luggage cart with handles for effortless pushing.

Making a luggage cart is a wise way to transport bulky bags to and fro. Luggage carts are useful when traveling with large groups or multiple suitcases or bags. For frequent travelers, especially those who are middle or senior aged, having a cart at home is a handy device for moving luggage from the house and into the car --- and vice versa. Craft your cart out of standard materials and be on your way to hauling luggage with ease in no time.

Things You'll Need

• Work gloves
• Safety glasses
• Dust mask
• .080-inch by 24-inch by 30-inch aluminum sheet
• Solder gun
• Solder wire
• Wet sponge
• Measuring tape
• Caster wheels, 8-inch by 2-inch (4)
• Bricks (8)
• 24-inch handle with panel (2)
• Carpet sheet
• Straight-edge knife
• Liquid Nails permanent epoxy (LN-203)

Instructions

1. Slide on work gloves, safety glasses and a dust mask to protect skin, eyes and lungs.

2. Lay the aluminum sheet on a flat work table. Plug in and warm the solder gun. Rub solder wire on the tip of the gun. Wipe the tip clean with a wet sponge.

3. Position the first wheel flush with one corner of the aluminum sheet. Move the wheel so the wheel plate is an 1/8-inch from both edges --- to provide space for soldering. Place the solder wire to where the metal plate on the wheel meets the sheet. Touch the tip of the gun to the wire to melt and solder the wheel plate. Solder the entire perimeter of the wheel plate. Repeat for the three remaining wheels.

4. Flip the cart upright. Place the cart onto the ground. Ask an assistant to hold and position one handle on one of the 24-inch ends of the cart. Adjust the handle so each bottom pole is 1/4-inch from the edge. Solder the handle to the cart. Repeat on the opposite end of the cart for the second handle. Purchase wheels and handles through your local hand truck and luggage cart parts manufacturer.

5. Measure and cut a piece of carpet to a size of 22 inches by 28 inches. Mix the Liquid Nails permanent epoxy (LN-203) as instructed via product label. Add epoxy to the bottom perimeter of the carpet. Fit and press the carpet to the top and center of the luggage cart panel. Purchase Liquid Nails permanent epoxy (LN-203) at your local home store. Liquid Nails permanent epoxy (LN-203) is specifically designed to bond fabric to metal.

References

• Signs US: Custom Aluminum Metal Signs -- Aluminum Size

Resources

• Pat Payne Distributors: Magliner Luggage Cart 4-zWheel Parts
• Liquid Nails: Liquid Nails permanent epoxy (LN-203)