It was actually very each to pick up the door turn 180 degrees and set down. I had my 10 year old son there to hold the cart still and grab the electrical connector.
Taking steps while carrying the doors was not fun!
The bottom has 1/2" plywood covered by a shipping blanket.
I haven't tackled the back doors yet. Wife won't let me take them off with the little ones. I will make one eventually.
It is 37" long and each door section is 6.5" wide. The pipe is 1-1/4" schedule 40 pipe. It is stronger than normal PVC. You can order the special connector pieces from Amazon. I then used screws to secure each section and pipe insulation to pad the upper crossbars. I also ordered the wheels from Amazon. I'll put links to the stuff on Amazon when I am not on my phone.
You can get the pipe from Lowes in 5 feet sections. I got 10 because you get a discount but I didn't use them all.
Consider yourself lucky. My wife freaks out from having a soft top. I eventually forced it, but taking the top off with the little one is a big no no :s
The measurements in the image are how long to cut the actual pieces of pipe. I tapped them in with a rubber mallet then went back and drilled 3/32 pilot holes for the screws. I put at least one screw in each link to a joint. The 1/2 plywood is just sitting on the bottom right now. I will screw it in to the pvc one day. I just folded up a shipping blanket for now that sits on top of the plywood. I might cover the plywood in carpet or foam one day. I also used duct tape to keep the pipe insulation on the 3 upper crossbars.
6 - 18"
6 - 37"
8 - 6.5"
It is pretty simple and I designed it on my own. It fits well in my garage between my jeep and the side wall.
Just let me know if you guys have any more questions. I think I covered it all.
The measurements in the image are how long to cut the actual pieces of pipe. I tapped them in with a rubber mallet then went back and drilled 3/32 pilot holes for the screws. I put at least one screw in each link to a joint. The 1/2 plywood is just sitting on the bottom right now. I will screw it in to the pvc one day. I just folded up a shipping blanket for now that sits on top of the plywood. I might cover the plywood in carpet or foam one day. I also used duct tape to keep the pipe insulation on the 3 upper crossbars.
6 - 18"
6 - 37"
8 - 6.5"
It is pretty simple and I designed it on my own. It fits well in my garage between my jeep and the side wall.
Just let me know if you guys have any more questions. I think I covered it all.
How tight do the doors fit in the rack. I used the other rack set up pictured in this thread and although it is solid, the doors are very tight between the uprights and I am worried about denting the sheet metal.
Agree! Good job and I'm going to give some extra thought to the bottom padding. Could use this for Freedom panels as well if you knew you weren't going to need them.
This is an awesome idea. For the back ones what do you think about just making two carts? They're basically the same just the back is a little narrower so maybe 30" instead of 37?
I only screwed. Using contact cement on PVC is a nightmare when trying to keep things square. Screws are so much easier and removable if needed in the future.
Love the cart, quick question while we are on this subject, just got my doors off yesterday they haven't been off ever, it's a 2002. I just got it a year ago. What a pain to get off the first time... Anyways does hanging them like this damage the doors in any way?
Thought I'd read it's not good for the window seals. I know yours are for a TJ and this is the JK section, but something like this is probably the same either way.
Made mine today and ive gotta say it turned out awesome. The measurements and link to fittings are perfect. Big kudos Orange for doing the leg work:drinks:
I used some anti fatigue mat from harbor freight on the plywood to cushion the door edges
Made mine today and ive gotta say it turned out awesome. The measurements and link to fittings are perfect. Big kudos Orange for doing the leg work:drinks:
I used some anti fatigue mat from harbor freight on the plywood to cushion the door edges
What did you use on the top as a cushion? It looks very secure. I used pipe insulators but they move around too much on my cart (PVC mounted on a furniture dolly)
I added up all the parts based on what was listed and it looked like about $100. I was pretty surprised at that, but I guess it's still cheaper than 170.
I was able to put together a stand for about $75. Throw in whatever the dolly cost me when i bought that previously and it probably comes in just shy of $100. I'd rather spend $100 and a Saturday morning messing with this stuff in my garage than buy it online anyway.
Great Idea!! Built mine using your plans the night I saw this (though the casters are currently awaiting replenishment)... my doors had been leaning against the wall for several days and this always made me uneasy. I no longer have to worry, at least about the front doors, and I am planning to make another set for the rear in the future. Thanks
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