Very happy I found your post. Will save a bunch of money vs buying one. Assembly starts tomorrow.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
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.