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PVC Door Cart

33K views 49 replies 32 participants last post by  Old Dogger 
#1 ·
Made this out of 1-1/4" PVC pipe.
 

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#11 ·
Is it a bit cumbersome trying to lift and place each door by yourself in the "slots?"
 
#15 ·
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!
 
#13 ·
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.
 
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#16 ·
Schedule 40 1-1/4" PVC pipe from Lowes. I bought 10 5' pieces because you get a discount for 10.

4-Way (8) - 2 Packs

http://www.amazon.com/gp/product/B00MNIYGSO?psc=1&redirect=true&ref_=oh_aui_detailpage_o00_s00

3-Way (2) - 1 Pack

FORMUFIT F1143WE-WH-4 3-Way Elbow PVC Fitting, Furniture Grade, 1-1/4" Size, White (Pack of 4): Amazon.com: Industrial & Scientific

Pipe Insulation (2)

Pipe Insulation, Semi-Slit, 1 5/8 In, 6 Ft - Weatherproofing Pipe Coverings - Amazon.com


Caster Fittings (4) - 1 Pack

http://www.amazon.com/gp/product/B00MNIYC38?psc=1&redirect=true&ref_=oh_aui_detailpage_o08_s01

Wheels (4) - 1 Order

Shepherd Regent Series 3" Diameter Vipor Wheel Swivel Caster with Side Brake, 7/16" Diameter x 1-7/16" Length Brass Band Grip Ring Stem, 120 lbs Capacity, Zinc Finish: Amazon.com: Industrial & Scientific

Screws - 1 package

http://www.amazon.com/gp/product/B00GYJOZNE?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00

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.
 

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#41 ·
Schedule 40 1-1/4" PVC pipe from Lowes. I bought 10 5' pieces because you get a discount for 10.

4-Way (8) - 2 Packs

FORMUFIT F1144WT-WH-4 4-Way Tee PVC Fitting, Furniture Grade, 1-1/4" Size, White (Pack of 4): Amazon.com: Industrial & Scientific

3-Way (2) - 1 Pack

FORMUFIT F1143WE-WH-4 3-Way Elbow PVC Fitting, Furniture Grade, 1-1/4" Size, White (Pack of 4): Amazon.com: Industrial & Scientific

Pipe Insulation (2)

Pipe Insulation, Semi-Slit, 1 5/8 In, 6 Ft - Weatherproofing Pipe Coverings - Amazon.com


Caster Fittings (4) - 1 Pack

http://www.amazon.com/gp/product/B00MNIYC38?psc=1&redirect=true&ref_=oh_aui_detailpage_o08_s01

Wheels (4) - 1 Order

Shepherd Regent Series 3" Diameter Vipor Wheel Swivel Caster with Side Brake, 7/16" Diameter x 1-7/16" Length Brass Band Grip Ring Stem, 120 lbs Capacity, Zinc Finish: Amazon.com: Industrial & Scientific

Screws - 1 package

http://www.amazon.com/gp/product/B00GYJOZNE?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00

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.
 
#20 ·
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?
 
#22 ·
Yeah I plan on another cart. I haven't measured it yet. It might be slimmer than the front door width too.
 
#27 ·
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.
 
#29 ·
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.
 
#31 ·
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

Just waiting on some wheels to show up



 
#32 ·
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

Just waiting on some wheels to show up
Very nice.

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)
 
#38 ·
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.
 
#44 ·
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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