Hardtop Cart / Holder DIY

[nextreme]

Lots of projects this weekend!

Here is how to build your own hardtop cart and save a $150.

2 2x4 cut to 29"
2 2x4 cut to 60"
1 1x2 cut to 60"
4 2x4 cut to 15"
4 caster wheels - if your garage is at a slant get locking casters
25 2.5" screws
Staple gun
Carpeting of your choice...

Total cost was $20 at home depot...$13 at Walmart for 2 yards of soft material...$14 at Lowes because my staple gun broke..

I carpeted the whole thing just because. Also, you will see I have my hard top set behind the front 2x4 but you can set it on top. I felt it was more secure that way.

I started by carpeting the 5 main pieces; the 2x4's and the 1x2.

Once those were carpeted I placed the 29" pieces under the 60" boards and clamped each corner going one corner at a time. Drilled pilot holes and put 4 screws in each corner.

Once the frame was built, I put the 1x2 6" back from the front board. That way there was space for the wiper. This board will hold the wiper off the ground if you do not secure the window to the hard top.

I then pilot holes and drilled/screwed the first 15" board 8" from the edge. Then screwed the 2nd 15" board to the top of that. Once they were both screwed down I carpeted them.

I then flipped it over and put the caster wheels on. I got wheels that spun 360*; if you do the same make sure there is room for them to spin.

Attached are the results!

**the blue tape was used to hold the window while we were lifting on to the cart..it was then removed.

Is this for a JLU? I have a 2022 JLU Willy's I'd like to build one for.

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[Texas_Yote]

Is this for a JLU? I have a 2022 JLU Willy's I'd like to build one for.

yup!

 

[RD-Man]

Thanks so much for posting these instructions! I plan on building it soon. Can someone measure the height of the highest point of the top from the ground and let me know what size casters you're using? I'm trying to thread the needle of using big enough casters to make it over some rougher terrain, yet low enough to make it through my shed door. Thanks very much!

 

[Smcdowell]

Thanks for this write up....I actually had everything needed sitting in the garage and was able to get this done in about an hour! Works perfectly. The only reason I have the strap on it is because the rack is pretty heavy and i didn't want it to tip. Thanks!

 

[Luke3.0]

Thank you for these instructions and examples! I have no room to store indoors, so I made an outdoor version, a little beefier build. I added 2 more 2x4s on the bottom to make the bottom flat. I used large pneumatic coasters to deal with uneven surface and to keep it elevated off the ground. Added pet resistant screen to the bottom for critter control (and ventilation), and glued/stapled a yoga matt for cushioning. I painted the wood with exterior flat black paint (because I had some). Once on the stand, I plan to cover the top with a soft blanket, then a water proof tarp strapped down around the parameter of the stand. The coasters added about $65, but worth it for my case. Thanks again!

 

[Maverick909]

Thanks for the good write up. Needed to make room in the garage. This helped out like a charm! Made two small changes due to Home Depot not having the 1x2 so I picked up up a 2x3. I moved it further out from the front from 6” to 7” and it worked perfectly

 

[Danny2203]

I feel like we all owe @Texas_Yote a beer at this point

 

[RickyPal]

Old post, I know, and This may be a silly question… but I am assuming this is meant for a two person lift effort. Anyone have a trick to do this solo? I can’t imagine one. Just curious, exploring all hard top storage / removal info I can find on forums.

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