Transporting a outboard motor is often a separate headache for the boat owner: a heavy unit weighing 20 to 100 kilograms is uncomfortable to carry in your hands, and when loaded into a car it is easy to damage or oil gasoline. A homemade cart solves these problems by turning the complex process of moving equipment into a simple walk on a pier or parking lot.
Creating such a device yourself does not require engineering education, but implies the presence of basic skills in working with metal and welding apparatus. Construction It can be made of available materials that are often left over after construction or repair, and the main thing is to correctly calculate the dimensions and mounting points so that the trolley is stable and can withstand the weight of your engine.
In this article, we will discuss all the stages of manufacturing, from the choice of materials to finish painting, you will learn how to avoid common mistakes when welding a frame and why it is important to choose the right one. wheelbase Self-manufactured fabrication will save a significant amount of money compared to buying ready-made factory counterparts.
Selection of materials and preparation of tools
The basis of any quality trolley is a strong frame, the best fit for its manufacture is a profile tube square or rectangular cross-section, the optimal choice will be a steel pipe the size of the steel pipe. 20x20 mm or 25x25 mm This profile provides the necessary rigidity, without weighting the structure beyond measure. Aluminum profile is not recommended for use due to the complexity of welding and less fracture strength during impact loads.
In addition to rolled metal, you'll need wheels, and you'll need wheels from garden carts or baby sleds, if the engine is light. powerful You'd better take inflatable wheels from a 300-400 mm garden wheelbarrow, which will provide excellent patency on soft ground and sand, where narrow plastic wheels will just get stuck, and you'll also need fasteners like M8 or M10 bolts, washers, nuts and, preferably, axle hairpins.
To fix the engine itself on the platform, you need robust screed belts with a ratchet mechanism or strong carbines. Don't rely on conventional ropes, because when shaking, the knot can untie, and stock up on anti-corrosion primer and paint to protect the metal from aggressive salt water and rust. Toolkit must include a Bulgarian, welding inverter, roulette, coal mine and marker.
If you don't have the ability to use welding, you might want to consider a bolt-based prefabricated joint, but that will require more precise drilling and cornering. However, welding is always more reliable and durable in vibrating conditions. Before you start, make sure that all tools are in good working order and personal protective equipment, such as a welder's mask and gloves, are on hand.
Design and design drawings
Before you cut metal, you have to make a schematic drawing, which will help you avoid overconsumption and errors in geometry. The standard motor cart is an U-shaped or L-shaped frame with a platform for the engine. The key parameter is the height of the rack on which the daywil (motor leg) will be based. It should correspond to the length of the active leg of your model. boat-engine.
When designing, consider the center of gravity. If the motor is too heavy, the trolley can tip backwards when lifting, and to avoid this, the axis of the wheels should be located closer to the vertical that passes through the center of mass of the load. Optimum width The frames should allow the cart to pass into the standard garage doorway or fold into the trunk of the car.
| Parameter | Recommended value | Note |
|---|---|---|
| Pipe profile | 20x20x2 mm | Steel St3 or St20 |
| Diameter of wheels | 300-400 mm | For cruising on the sand |
| Stand height | 380-550 mm | Depends on the deadville leg. |
| Load capacity | 80 kg | With a 30% safety margin |
It's important to have stops that keep the motor from moving sideways, which can be welded corners or special rubber-covered beds, rubber upholstery that prevents scratches on the paintwork of the engine, and you should also think about a handle for transportation, which should be comfortable and at a height comfortable for your growth.
Calculation of pipe length
One standard-sized trolley will require about 4-5 meters of linear profile pipe, and always take material with a margin of 10-15% for trimming and possible errors when cutting.
Step-by-step instructions for assembling the frame
Start by slicing the workpieces according to your drawing. Use the angler to check the right angles, because the frame skews the wheels. First, assemble the base, the rectangle on which the motor will rest. Weld the corners with the grips, check the diagonals, and then boil the seams completely. Quality seam - guarantee the durability of the structure.
Next, weld a vertical rack. It can be straight or it can have a bend that replicates the shape of the trunk of the boat, which will ensure a tighter fit. At the top end of the rack, you need to fix the pad or the stop for the deadville leg. Often you use a piece of pipe larger diameter or a metal plate with a rubber pad. Make sure that the angle of the motor is in line with its transport position.
So the next step is to mount the wheel axle, which can be welded to or passed through the frame, and the second option is preferable because it allows you to use a single stud, which increases the stiffness. If you use ready-made wheels with bearings, the axis should match exactly their internal diameter. The gaps should be minimal, but allow the wheels to rotate freely.
☑️ Frame welding stages
Once welded, all the elements must be cleaned with a petal-circle Bulgarian, which not only improves the appearance, but also allows for a high-quality corrosion coating, the scale and rust must be removed completely, and in places where the belts or stops are attached, you can weld small hooks or ears. Final assembly includes the installation of wheels and checking the stability of the entire structure on a flat surface.
Motor fastening and fixation system
The most important thing is to ensure that the engine is securely attached, the motor should not hang around or be able to slip, and for this purpose, the frame provides two levels of fixation: the support of the deidville leg and the mounting point for the deadville (carrier handle or special bracket). tie-beltThey are the ones that cover the motor body and frame, pressing them against each other.
If you plan to transport the motor in an upright position (which is not always recommended for two-stroke engines due to oil leakage), make sure that the carburetor or lubrication system is protected from leakage. In a horizontal position, the motor lies on its side, relying on a specially provided frame projection, in which case it is important that the muffler does not touch hot parts or sharp edges of metal.
⚠️ Warning: Never transport an outboard motor if it leaks fuel or oil, and this can cause fire or damage to the rubber parts of the trolley and wheels.
For added safety, you can use soft pads from the car chamber or foamed polyethylene in the contact areas of the frame metal with the engine body, which will extinguish the vibration and protect the paint coating from abrasion. Fastening knots They should be easily accessible so that you can quickly lock or release the motor even with gloves on.
Lubricate the bolt thread with graphite lubricant before assembly – this will prevent the joints from boiling after contact with salt water and will make it easier to maintain the trolley in the future.
Protection against corrosion and painting
The metal trolley will be in constant contact with moisture, salt and sand, so good corrosion treatment is critical. Just paint the rusty metal is a waste of time. First, the surface must be degreased with solvent, then treated with a rust converter if it already appears. After drying, apply the soil over the rust, which creates a protective layer.
The best finishing coatings are alkyd enamels or special paints for metal structures that are weather resistant. You can use hammer paint that hides small defects in welding and looks aesthetically pleasing. You should apply the paint in 2-3 thin layers, allowing each to dry according to the instructions. Pay special attention to welds and inner corners where moisture stagnates most often.
If you want to make the cart more functional, you can add elements of stainless steel or plastic in places of constant friction. Durability The product depends on the quality of the surface preparation before painting. Don't be lazy to clean the metal to shine - this will provide excellent adhesion of the coating.
Operation and care of the trolley
After every trip, especially at sea, the cart must be rinsed with fresh water. Salt quickly corrodes even painted metal and wheel bearings. Periodically check the condition of the wheels: pump tire pressure, lubricate bearings. If the wheels are plastic, inspect them for cracks that can occur from impacts on stones.
Keep the cart in a dry room, hanging or mounted on the stands so that the wheels do not deform from constant pressure. Check the welds once a season for microcracks. When you find defects, immediately brew them without waiting for the structure to collapse. Regular maintenance This will extend the life of your homemade device for many years.
Don't overload the cart with a weight greater than the calculated one. Although the profile pipe is strong, excessive loading can cause the axis to bend or deform the frame, making transportation unsafe. If you plan to carry different motors, make sure that the support points are universal or easily adjustable.
Homemade trolley from the profile pipe is an economical and reliable solution, which, with proper anti-corrosion treatment, will last longer than many factory analogues.
Frequently Asked Questions (FAQ)
Can you make a cart without welding using only bolts?
Yes, it is possible, but it will require more precise fitting of parts and the use of connecting corners. The bolt connection is less resistant to vibration, so you will have to check the nut tightening regularly and use growers or a carving fixator.
Which wheels are better to choose for sand: inflatable or cast?
For sand, wide inflatable wheels with a diameter of 300 mm are definitely better suited. They have less pressure on the ground and do not fall. cast plastic wheels are designed only for smooth hard surfaces (asphalt, concrete).
Do I need to remove the motor from the transom for transportation on the trolley?
Yes, the cart is designed to transport the removed engine, and transporting the motor on the transom of the boat requires a completely different design of the trailer or keel cart for the boat itself.
How to calculate the height of the trolley rack?
The height of the rack should correspond to the length of the deidvile leg of your motor (Short, Long, X-Long), so that when installed on the trolley, the motor occupies a transport position close to the vertical or prescribed by the instructions, without falling down and not touching the ground prematurely.