DIY Hardtop Cart - JK-Forum.com - The top destination for Jeep JK Wrangler news, rumors, and discussion

Notices

DIY Hardtop Cart

Reply

 
 
Old 05-07-2009, 05:10 PM
  #1
JK Enthusiast
Thread Starter
 
Riptyd's Avatar
 
Join Date: Oct 2008
Location: Fontana, CA
Posts: 130
Thanks: 0
Thanked 0 Times in 0 Posts
Default DIY Hardtop Cart

I am planning on taking my top off tomorrow but I needed a way to move and store the top. I have seen several ways to hang it on the side wall of the grarge or suspend it from the ceiling. For me the most practical way to store it would be a cart to put it on. There are several available at the shops starting around $140 I had seen a few board pages that talked about building your own out of wood. I found the following parts list and dimensions::
I am not sure where these plans originated, I just found them on the web. I was recently contacted by David Mellon @. http://performancejeepchrysler.com/
He claims that I have plagerized these instructions and materials list. If he is truly the originator of these directions , I apologize. Infringement was not my intention. The pictures are mine and it is my jeep. I hope he acepts my apology and is statisfied with me giving him credit for his contribution. Otherwise I will have to remove this post.

Parts list
1) 1 59 inch length of 1x2
2) 2 30 inch lengths of 2x4
3) 2 59 inch lengths of 2x4
4) 6 6 inch lengths of 2x4
5) 8 1/2 inch long wood screws
6) 2 1 1/2 inch wood screws
7) 20 3 inch long wood screws
8) 4 2 inch swivel wheels. Poly, plastic or metal wheels will all work - locking wheels are optional - recommended if your storage surface is uneven.
9) Optional: Two 12x2 cuts of Foam, felt or soft fabric






Tools needed for construction / assembly

1) Philips screw driver OR Philips bit for electric drill
2) Electric Drill
3) Hand saw OR power saw
4) Drill bit 5/32

Construction / assembly instructions

1) Lay the two 59" 2x4's parallel to each other on level and solid work space. Floor works well.
2) Lay the two 30" 2x4 pieces over the top of the longer (59" pieces) creating a rectangle (Fig 1)



3) Drill two 5/32 starter holes for the screws in each corner
4) Screw each corner together filling all holes using 3" screws
5) Place each wheel on the outside edge of the 59" piece of 2x4 allowing enough room for the wheel to turn 360 degrees (Figure 3)



6) Screw wheels in place using at least two screws per wheel placed diagonally to each other using 1/2" long wood screws.
7) Turn rack over with wheel side down (Figure 2)
8) Measure 9.5 inches in from either side, place the 59 inch 1x2 at that location. Drill a 5/32 starter hole on each end then screw in place using one 1 1/2 inch screw on each end. (this window bar is in place to hold your rear window closed)




9) On the farthest 59" 2x4 from the window bar measure 10.5 inches from each end and mark these locations for the 6" rear support pieces to be installed (Figure 2).
10) Place one 6" 2x4 on each of your marked location, drill two 5/32 starter holes in each piece then screw in place using two 3" screws per block. Continue stacking, drilling starter holes and screwing 6" pieces in place until each stack is 3 pieces high ( Figure 2)
11) Optional: Pad the tops of the rear support pieces with foam, felt or soft fabric



12) Figure 4 shows placement of hardtop on the dolly.

Unfortunately there were no diagrams or pictures when it said figure1-2-3-4 so That part was a little more my imagination. I bought the materials which cost about $22.00. The caster wheels I had picked up at a yard sale for some unknown future project. it took me about 90 minutes to build it on the drive way. later tonight or tomorrow I will post my build pictures to go with the assembly instructions. I think it will do the job nicely.


and before you say it:

I will post them asap, but right now I have to get the boy to a Cub Scout Meeting

Last edited by Riptyd; 10-18-2009 at 10:23 PM.
Riptyd is offline  
Reply With Quote
Old 05-08-2009, 07:44 AM
  #2
JK Enthusiast
Thread Starter
 
Riptyd's Avatar
 
Join Date: Oct 2008
Location: Fontana, CA
Posts: 130
Thanks: 0
Thanked 0 Times in 0 Posts
Default



pictures have been added.

Photo credit:http://www.flickr.com/people/seraphimc/
Riptyd is offline  
Reply With Quote
Old 05-08-2009, 03:01 PM
  #3
JK Enthusiast
Thread Starter
 
Riptyd's Avatar
 
Join Date: Oct 2008
Location: Fontana, CA
Posts: 130
Thanks: 0
Thanked 0 Times in 0 Posts
Default

Just a few last pictures for y'all




Last edited by Riptyd; 05-08-2009 at 05:20 PM.
Riptyd is offline  
Reply With Quote
Old 05-08-2009, 08:48 PM
  #4
JK Newbie
 
Join Date: Oct 2008
Location: Saddle Brook, NJ
Posts: 18
Thanks: 0
Thanked 0 Times in 0 Posts
Default Very nice work

I like the way you built this and wrote this up. Well done! I will do the same or use the "moving dolly" paired together (since I have 2 dollies available.) Since my garage doesn't have the height to allow for a hoist, the dolly seems like the best method. What is that rod with the bungee cord? I'm gonna guess its a clothes rod and holds the window closed.. I know some places sell clamps, but this seems like a good way to hold the window. I suppose my fears regarding the hardtop are associated with dropping it or knocking it over. I plan on putting it on a dolly and then lash it to the wall. Right now it is sitting on the garage floor roof side down. I bought a moving blanket and it is sitting on that. Once I make the dolly, I will cover the top with the blanket.

Again nice write up, and nice Jeep too!
jp523 is offline  
Reply With Quote
Old 05-09-2009, 05:25 AM
  #5
JK Enthusiast
 
Join Date: Jul 2008
Location: warren county nj
Posts: 381
Thanks: 0
Thanked 0 Times in 0 Posts
Default

whats that member for? is it holding glass? Attachment 23838
atuldo is offline  
Reply With Quote
Old 05-09-2009, 07:02 AM
  #6
JK Enthusiast
Thread Starter
 
Riptyd's Avatar
 
Join Date: Oct 2008
Location: Fontana, CA
Posts: 130
Thanks: 0
Thanked 0 Times in 0 Posts
Default

Yes the 1x2 cross piece is designed to hold window. My issue was that when your lowering the top off the jeep the window can flop open and potentially be damaged. Looking at the commercial unit, I noticed things that were designed to keep that from happening. I used a garment rack that I could expand to the length needed, then used a bungee cord. Worked awsome. You could leave the rod/bungee on and skip the 1x2 in the build process.
Riptyd is offline  
Reply With Quote
Old 07-06-2009, 10:42 PM
  #7
JK Newbie
 
Join Date: Jun 2009
Location: Warrenville, IL
Posts: 1
Thanks: 0
Thanked 0 Times in 0 Posts
Default I have made a quick plan for this, it works great!!

here are the plans. . I tried to upload a pdf but it was to big. .
Attached Thumbnails Click image for larger version

Name:	jeep_dolly.gif
Views:	90433
Size:	17.0 KB
ID:	26594  
bsamoose is offline  
Reply With Quote
Old 07-07-2009, 12:51 PM
  #8
JK Enthusiast
 
Fermin's Avatar
 
Join Date: Oct 2008
Location: Anchorage, AK
Posts: 266
Thanks: 0
Thanked 0 Times in 0 Posts
Default

Need it a little larger. My eyes are getting older

Fermin is offline  
Reply With Quote
Old 07-08-2009, 02:20 PM
  #9
JK Freak
 
YellowToy's Avatar
 
Join Date: Apr 2008
Location: Mt. Pleasant, SC
Posts: 888
Thanks: 0
Thanked 0 Times in 0 Posts
Default Need a bigger picture

Great write-up. As soon as I clear some space in my garage I will need to build one of these.

but... I can't read the PDF. Can it be posted to photobucket or something?
YellowToy is offline  
Reply With Quote
Old 07-08-2009, 08:01 PM
  #10
JK Newbie
 
Rockindoc's Avatar
 
Join Date: Mar 2009
Location: middle of nowhere, Nevada
Posts: 90
Thanks: 0
Thanked 0 Times in 0 Posts
Default

I'll be at Home Depot this weekend.
Rockindoc is offline  
Reply With Quote
 
 
 

Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
jarettms
JK Accessories & Misc Parts
2
04-24-2009 09:35 PM
Milkman
JK Accessories & Misc Parts
2
11-04-2008 08:07 PM
snosurferjeep
JK Accessories & Misc Parts
4
04-09-2008 07:04 PM
Gunslinger
JK Talk
2
11-26-2007 06:55 PM
nextreme
Stock JK Tech
17
03-31-2007 03:26 AM

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -8. The time now is 07:48 AM.


 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: