How To Build a Kayak Storage & Loading Cart the EASY WAY!

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Nowadays, kayak storage and loading carts are essential! The reason? Kayaks are heavy, and lifting them without a storage and loading cart is certainly no fun. But it’s easy to eliminate the pain of loading and unloading a kayak onto a truck bed with this easy to make kayak storage and loading cart. I’ll show you how to make it in just a few minutes!

As we at Kayak Angler have seen, there may be no more popular home project for today’s heavy fishing kayaks. -- KayakAnglerMag.com

Requirements

When scouring YouTube for how to make a cart, I had three requirements in mind. First, I needed the cart to disassemble easily. After all, I have a two car garage and at times I want to park both cars inside. In order to do that I'd have to hang my kayak on my storage rack and disassemble the cart. This cart disassembles in 2 seconds or less! Next, I needed the cart to do more than just store my kayak in the garage, I needed it to go the extra mile and assist me in loading my Hobie Outback into the bed of my truck. Wait till you see how this one pivots to do that. And finally, when I unloaded my kayak I wanted to be able to hose it down and have the cart not be damaged by the water. This design even helps to drain the water!

Design Credit

The overall design of this cart came from a former YouTuber, Lef Yak Fishing. He's since left YouTUbe and encouraged me to make a video about the cart instead. Thanks Lef!

Parts

Here’s what you’ll need as parts.

Tools

  • Drill
  • Carpenters Square
  • Socket Set or attachments for your drill
  • 7/8" paddle bit to countersink your lag bolts
  • 1/4" bit to drill pilot holes for your lag bolts and to create drain holes
  • 1" bit to drill the top of the PVC
  • Saw to cut your lumber
  • Marker
  • Sandpaper

Instructions

So let’s get started.

Step 1 : Cut the wood & PVC to size

  1. The 4x4's should be exactly 21 1/2" and perfectly square.
  2. The 2x4's should be 33 1/4" or slightly longer as explained in the video
  3. The PVC should be 8' long and you can optionally add a 45* angle cut as seen in the video

Step 2: Drill the holes in your 2 x 4’s

  1. I made a Jig to help me countersink the holes on each end of the 2x4
  2. Align it and drill partway through your 2x4, just deep enough to recess the head of your lag bolt and a washer.
  3. The drill bit should be wide enough to receive your socket
  4. Then drill out the center with your pilot hole bit.

Step 3: Drill the pilot holes in your 4x4’s

  1. Align the 2x4 to the 4x4 and make it square
  2. Using the pilot hole in your 2x4, drill the pilot hole into your 4x4, and bolt it on with a 4” lag bolt and a washer
  3. Check to make sure you’re square and attach the second bolt
  4. Repeat this process for all four corners, one bolt at a time, and your box is complete.

Step 4: Mark your box for the positions of the PVC.

  1. 1st measure your kayak, the width of the indentions on the bottom. For a Hobie Outback they are 11.5” apart. That means you want your PVC to be 11.5” apart, center point to center point.
  2. Using your square mark your box with those lines. Also, make an X on that line in the center of the 4x4

Step 5: Mark your PVC

  1. Layout your PVC on the ground parallel to the box and center it so that the amount of tubing to either side of the box is even.
  2. Spin the PVC until the line printed on it is pointing straight up. Now mark that line for where it will connect to the 4x4
  3. Using the pilot hole bit, drill through the top and bottom of the tubing, and repeat for the hole where the tubing will attach to the other 4x4
  4. Now spin the pipe over to the other side, and using a larger paddle bit, make the hole on the top large enough to fit your socket into it.

Step 6: Attach the PVC to the box using the 3” lag bolts and a washer

  1. It’s helpful to lay the PVC onto the box and looking down through the holes, align the pre-drilled pilot hole with the x.
  2. Drill the pilot hole in the 4x4 and attach the 1st lag bolt loosely.
  3. Now you can swing the PVC into place until you see the line on the other 4x4 through the second hole in the PVC. Simply mark and drill your pilot, then attach it with another 3” lag bolt and washer.
  4. Repeat the process for the second PVC tube and you’re all done
  5. Use a flashlight in the tube to assist with sight

Step 7: Attach the Feet

Step 8: Assemble your ULINE cart per the instructions

Step 9: Drain Holes

  1. Drill drain holes at a 45* angle through the corners of the cart and tray; you’ll also want some in the center

Step 10: Finally, drop your box into the top tray and you’re ready to go.

~Kayak Fishing Addict

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December 29, 2021
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