PVC Kayak Cart
by John, aka pteropus

After dragging my boat through the sand for about 50 yards due to an EXTREMELY low tide I decided it was time to build a kayak cart. After looking around on several web sites I decided that nothing I saw was quite what I wanted so I took several ideas, melded them together, and this is what I got.

I’ll show, step by step how it went together. However, I am not giving measurements for several reasons. First, because I am not finished tweeking this version. Second, because I believe the cart should be custom fit to your kayak. And finally, because playing around with the general model and customizing it for your own needs is half the fun.

Component List:

8 ft. ¾” Schedule 40 PVC

2 - 8” Lawn mower wheels w/½” hub

6 ft. pipe insulation

4 - ¾” PVC Ts

4 – ¾” PVC 90º elbow

2 – ¾” PVC 45º elbow

2 – ¾” PVC Plugs

2 – ½” x 3” SS Carriage Bolt w/nuts

4 – SS ½” ID Washers

2 – 1” x 6’ nylon tie down straps

Assembly:

1) Drill a ½” hole in the center of each plug. Place the carriage bolt thru the hole. The bolts I used had to be hammered into place. Slide washer-wheel –washer – nut onto bolt. If you can find a nylon lock nut use that if not superglue/weld nut into place to it wont tighten during transport.

2) Glue a T to each wheel/plug as shown.

3) Determine the with of the supports on your kayak. For me this was just inside of the chine, on SOTs it may be different. Cut the PVC for the axle approximately 2” short of this width.

4) Attach the wheel to the axle. I did not glue the wheels to the axle so that I can break down the cart and store it on my rear hatch. Whether you decide to glue the wheels or not will depend on your storage needs and the fit of the PVC.

5) Next cut 2 pieces of PVC the same length for the uprights. This length will depend on length of your kayak and where you place the cart. (Mine is currently about 10”, but will probably be shortened.) Glue a T to the top of each upright. Place the uprights in the remaining hole in the wheel T.

6) To make the supports cut 4 equal lengths of PVC. Glue a 90º elbow to one end of each piece. Attach (DO NOT GLUE YET) the support arms to the upright’s Ts. Turn the 90º elbows so that they meet the 45º elbow. Measure the needed length of PVC and cut to fit. This may take a little trial and error. Draw a line from across each arm/elbow fitting once squared. This will help with the glue up later. Once the supports are properly fitted cut insulation to fit.

7) Glue the support arms into the 45º elbows. Slide on the insulation. Glue the arms to the 90º elbows. Place supports in upright T (DO NOT GLUE) and square all joints BEFORE glue sets. Once glue is set pull support arms out of the Ts and slide on remaining insulation.

8) Finally. Place kayak on cart and strap down. NOTE: Only one strap is shown in photo. Straps should be placed at 90º elbows, both front and back.

Again, I have given you general directions. This cart is not completed yet, nor is it perfect for every kayak. Use this as a guide to customize your own cart.