Archive for the ‘Projects’ Category

Body Cart Construction

Posted: October 17, 2011 in Projects

I needed to find a creative solution to a limited amount of space in the home garage in order to do a complete frame off restoration.  We’re fortunate to have a three car garage but one committment I made to my bride was that her car would not get kicked out of the garage during this project.

What complicates issues further is the fact that I have two 66 Bugs sitting in my garage due to “My First Mistake”.  Since the first car will be a donor I want to keep it in the best shape I can and with the fact we are heading into our rainy season here in the Pacific Northwest (or what everyone else calls Fall, Winter, Spring and most of Summer) storing it outside is not ideal.

I found various cart designs that would be more than adequate if I had two stalls in my garage to dedicate full time to just this one car but I don’t. I was fortunate to stumble across two seperate designs on line by other home restorers that had characteristics that met some of my needs, neither fit all the criteria but they did inspire me.

Ultimately, it had to be affordable to build as we are on a budget, I need the body at a reasonable height once loaded on the cart for working on it, once resting on the cart the heater channels needed to be fully exposed, it had to be mobile and it needed to be able to roll over the rolling frame for storage. I decided on a design made with 4″x4″ lumber, metal brackets and wheel casters.

I started with [4] – 8′ – 4″x4″ posts, [1] –  6′ – 4″x4″ post, [16] – L shaped support brackets, [8] – flat metal plates, [1] – 36″ long 1″ dowel cut into 3 1/2″ lengths, [4] – 5″ wheel casters, [16] – 1 3/4″ lag bolts and a box of 1 1/4″ wood screws.


I left two of my 8′ lengths as they were and cut two others down to 6′ lengths. I then cut the remaining post so that I had a total of four 24″ lengths. Then using a flat bottom bit I drilled one inch holes at 1 3/4″ depths at the ends of each cut lumber pieces as shown below. I then drove the dowels into the ends of my 8′ lengths.


With a little glue in place I then hammered the 24″ lengths in an upright position. After checking the vertical alignment and verifying the angle was square I then mounted the L shape brackets using the 1 1/4″ wood screws.


Once the brackets were mounted I then placed the flat metal plate on the reverse side of the joint for added support. The 6′ cross supports were then put in place utilzing the same method. Four wheel casters then finished off the construction of the cart.