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  1. #1
    steve45's Avatar
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    The Shop Cart Revisited

    When I started buying the larger Kawasaki JetSkis, it became apparent that I would need a larger shop cart on which to work on them. My old, small cart worked, but it seemed rather 'tippy' with an 1100 pound 'Ski on it. I just didn't feel good about rolling it around my shop. The newer 'Skis are taller than the older ones, and I sometimes had to use a step ladder to get be able to reach deep into the hull. Getting the center of gravity in the right spot over the cart was a worry, too.

    I set out to build a larger, more stable cart. I wanted one that would be adjustable in height. I have hulls of different widths, so it would be nice if I could compensate for that, as well. I realized that this thing would take up a lot of room in my shop--not good. It would be great if I could make it fold up!

    Well, here it is:

    By making the height adjustable, I was also able to make the sides different heights. I could tilt the 'Ski to make it easier to reach into it.


    It has 6" rotating casters with brakes. It can roll over pebbles, wires, etc. without the fear of tipping over.

    There are 4 ball rollers on one end so it can be moved around the shop when it's folded up. A handle is mounted on the opposite end to aid in lifting it to the vertical position for storage.


    The bunk rails can pivot almost 90° in either direction, but a locking mechanism is used to hold them in place. A hex head bolt with a stop allows me to adjust the position of the locking handle.


    Notice that the vertical struts can be mounted into two different sockets on each side of the frame, allowing for 3 different hull widths:


    The bunk rail assemblies can be removed, the base tilted up on the storage rollers, then the bunk rails inserted into brackets on the bottom of the frame:


    The whole package in the storage configuration is 78" high, 55" wide, and only 13" thick:


    When folded for storage, the bunk rail assemblies are secured in brackets along with their mounting pins and clips:


    It's big, but everything is bigger in Texas. It's heavy, and that's a problem. Materials were about $400. Aluminum would be lighter, but a lot more expensive, and I can't weld that (yet). The sockets were cut from standard 2" trailer receivers. The struts were 2" square tubing. The locking pins are standard 5/8" trailer hitch pins. I made the locking handles on my lathe.
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  2. #2
    My Jet Ski drinks more than yours Glenozzy's Avatar
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    I think i am turned on right now! how much would it cost?

  3. #3
    moparguy's Avatar
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    Awesome build!!! One of the best thought out carts I've ever seen!!!

  4. +1 by:


  5. #4
    Hurricane1000's Avatar
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    Thumbs up on that!

  6. #5
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    That turned out excellently Steve, I am seriously impressed and will be replicating it.

    Sean

  7. #6
    Thor's Avatar
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    Steve!!!!!!!!

    Check or Money Order, okay? (I’ll pay for the shipping, of course)!

    Hook ... me ... up!!!!!

  8. #7
    This is how I run a jetski shop in the desert nmpeter's Avatar
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    yeah, I'm in the market for one too. I'm officially too old to be doing the preztel dance working on some of these trailers with two skis on them

    I just did two blowers on some 05's and I swore I'm never doing that again anytime soon

  9. #8
    Ultra 15f's Avatar
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    Nice work it looks great.

  10. #9
    steve45's Avatar
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    Thanks, guys! Manufacturing it and shipping it in its present form just isn't practical. However, I've been thinking again...

    With a bolt-together frame, and some jigs for drilling and welding, well, it might be doable.

    If people didn't want the collapsible feature (no sockets to store the bunk rails and no 'feet' with rollers) that would probably reduce the price by about $200. Just thinking out loud and I'm not saying that I would actually build & sell these things, but I think the collapsible version would go for about $900, non-collapsible version would be about $700 PLUS shipping and any applicable taxes.

    I don't have any drawings, yet, but if anybody wants to build their own, I can create some sketches and provide some details that I learned through trial & error. There are several features that are not visible in the photos.

  11. #10
    Thor's Avatar
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    Dayum, Steve ... if there is such a thing as “shop porn” that cart is IT!

    (I keep coming back to this page and finding myself drooling ... just, dayum)

    Nothing like real craftsmanship!

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