How to Build a Kayak Cart

A kayak cart is the easiest way to transport a kayak to and from your vehicle or to a nearby beach, but it can cost up to $150 to buy one. Save that money by building one yourself. Kayak carts consist of a base that holds the wheels and axle in place and top bars that cradle the kayak. The size of the cart and wheels will depend both on the size of the kayak and the materials you have available.

Things You'll Need

• Measuring tape
• One 10-foot length of 3/4-inch PVC pipe
• Glue for PVC pipes
• Hacksaw
• Six 3/4-inch PVC T-joints
• One 3-foot length of 5/8-inch hollow steel rod
• Vice
• Drill
• Metal drill bit
• Two pneumatic wheels
• Two cotter pins
• One foam pool noodle
• One tie-down strap with fastener

Instructions

1. Make the base that will hold the wheels and axle of your kayak cart. Measure the width of your kayak at its widest point. Cut two pieces of PVC pipe to that length.
   Following the directions on the glue container, insert one of the cut pieces of PVC pipe into the arm of a T-joint.
   Take a second T-joint and connect it so that one of the arms of the top of the T attaches to the stem of the first T-joint.
   Take the second piece of cut PVC and connect it to the stem of the second T-joint, so you have two horizontal bars running parallel.
   Take two more T-joints and use them to connect the open ends of the two PVC pipes, mirroring the T-joint configuration on the first end. You should have a rectangle.
   Measure and cut two 2-inch pieces of PVC and connect one to each of the open ends of the sideways T-joints.

2. Build the axle. Use a vice to hold the rod steady and drill a hole through one end of the steel rod that is large enough to accept the cotter pin.
   Next, measure where the second hole needs to go. The steel rod will run the width of the scupper holes as well as through the T-joints and through the wheels.
   After drilling the second hole, cut the rod to fit the width of the PVC pipe, T-joints and wheels.

3. Add the wheels. Take one wheel and slide it onto the steel rod and use a cotter pin so that it goes through the hole and attaches to the wheel. Slide the other end of the rod through the PVC pipes and T-joints and attach the second wheel and cotter pin.

4. Make the top bars for your cart. Take a T-joint and attach a short piece (2 to 3 inches) of PVC pipe to both arms on the top of the T. Do this again so that you have a pair.
   Next, cut a foam pool noodle so that it's the same length as the short pieces of PVC and slide the foam over the PVC pipe to cover it.
   Attach these to each of the open ends of the T-joints on your base. These are the top bars your kayak will rest on.

5. Secure your kayak to the cart. Simply lay the kayak down on top of the top bars and take a tie-down strap and run it under the top bars and wrap around the kayak. Secure with a fastener such as a cam buckle or ratchet. To tow the kayak, simply grasp the kayak using either an end handle or by grasping the tie down strap, tilt the kayak up and just pull it along on the cart.

References

• How to Build a Kayak Cart