How to Make a Dolly Yourself
Building and owning your own dolly can make it easy to move heavy loads, tools and furniture, especially if the dolly can handle over 600 pounds. If you're well-prepared, you can take care of a day's work in a few hours.
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Things You'll Need
- 1-inch thick by 20-inch long by 28-inch wide board made of hardwood, such as oak
- 3/4-inch thick by 22-inch long by 12-inch wide hardwood board
- Four 4-inch hard rubber wheels
- Four 3-inch stainless steel casters, plate mount, with brakes
- 48 nails
- Saw
- Hammer
- Small wrench
- Measuring tape
- Pencil
- Sandpaper, 220-grit
- Sanding block with 120-grit and 180-grit sandpaper
Instructions
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1
Before cutting any wood, use the measuring tape to make sure the deck board is 20 inches long by 28 inches wide; a hardwood board bought from a hardware store or a lumber yard might not fit those exact dimensions.
Sand the deck board to make the surface even and smooth. Remove any rises or jagged edges that might catch against items placed on the deck. Use a sanding block with 120-grit and 180-grit sandpaper.
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2
Cut two deck supports. These are the two boards that run the length of the dolly. Prop the deck and provide mounting places for the wheels and casters. Cut 10 inches from the width. Trim the 22-inch length to the exact length of the deck. Use the saw to divide the 10-inch wide board into a 4-inch wide support and a 6-inch wide support.
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3
Mount the two supports under the deck. Place the 4-inch board at one end of the 28-inch deck and the 6-inch board at the other end. Hammer the supports to the deck with nails. Use 8 nails along the two long sides of each support. Leave room in the four dolly corners for the casters. Sand the wood faces smooth with 220-grit sandpaper.
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4
Attach the casters in the four corners. Align a caster plate straight in a corner, with the long plate side parallel to the long deck side. Nail the plate to the support with four nails. Repeat for the 3 wheels remaining.
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5
Set the wheels in the casters. Place each hard rubber wheel in its caster. Send the bolt through the wheel and secure with a wrench. Give the dolly a test roll. Add a heavy item and test again. Fine-tune the wheel alignment so the wheels sit straight and turn smoothly.
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Tips & Warnings
• Place the heavy part of an item on the side with the 6-inch wide support.
• Choose wheels that withstand heavy weight and do not wear out.
• Use sturdy casters. If the casters bend, turns with heavy weight will become rough and difficult.
