Jeep Door Cart

We have a tiny garage, and its full of stuff, so a year ago when we bought our jeep, i looked for a way to store the doors when off. I dont have any wall space, so the PVC rack/cart seemed like the best solution. While it did its job over the last year, I wasnt happy with it as it took up almost all of my available floor space, so i searched for something else. this is the solution i found. There are manufactured carts like this available but they cost $400-$500. I built this with about $100 in wood, carpet, screws from Home Depot. I already had the castors.

I posted this on a couple FB Jeep groups, and and had lots of requests for directions on how to build this. I didnt take any pictures of assembly, so these directions were put together after the fact, so hopefully they will make sense.

While i attached the top piece one way (see pic), these directions recommend using angle brackets. So i dont really have pictures for. Hopefully you will get it.

I got most of this from HomeDepot for about $100US, but i already had the castors and velcro straps.

6x 2″x4″x8′

4x castors

1 box 3″ screws (see picture – I used construction type screws, and not drywall, but note that these require a special bit (supplied in the box))

Section of outdoor carpet (I just picked up some remnant piece at HD)

a couple pieces of bungee cord or velcro straps.

Optional Parts List #1

4x 1/2″x4″ bolt

4x 1/2″ nut

8x 1/2 washers

4x 1/4″x4″ bold

4x 1/4″x4″ nut

8x 1/4″ washers

Option Parts List #2

angle bracket (optional)

Cut 5 of the 2x4s to six foot lengths.

Cut the last 2×4 in half (4′).

Cut the left over 2′ pieces, cut to 18″ lengths. <= I guess you dont have to do this, the base would then just be 6′ x 2′. I wanted it as small as i could for space. 18″ wide looks about as narrow as i would go.

If you dont have a saw at home, you can have the 2x4s cut at Home Depot (and i’m sure Lowes will do this too).

You should now have five – six foot 2x4s, five – 18″ 2x4s, and two – four foot 2x4s. (the rest you dont need)

1. Screw two of the six foot 2x4s together like this (see pic). 4 screws evenly spaced along the length should do.
2. Screw two of the 18″ 2×4 pieces to the ends like this (see pic). Two or three screws should do.
3. Screw one of the 18″ 2×4 pieces about 31-32" from one of the ends (see pic). Two screws on each side should do. This will divide the base into two sections. The larger of the two will fit the front door, the shorter of the two will fit the back door.

Measure and mark at 9″ on each of the end pieces. measure and mark 1 3/4″ on the end of each of the four foot 2x4s. Line up the two marks to help center the posts

There are two ways to attach these side pieces…

I wanted to be able to disassemble this, so i used bolts to attach them (1/2″ parts list option #1)

If bolting them together, drill holes, and bolt them together.

If you dont want, or feel that you wont need to disassemble this, you can just screw these pieces together.

Screwing them together is the easiest. Two screws for each piece should do.

** Note when i put this together i put the posts on the outside of the frame, dont do this, as the top piece will be too short. Attach it on the inside of the frame!

I am sure there are other ways of doing this, but here are two.

Most of you will probably want to use the angle bracket option as its simpler (option #2 parts list). I think I would use a roofing type of angle bracket, as opposed to an angle bracket like you would use for making a picture frame. If you dont know what a roofing type angle bracket is, ask a HomeDepot lumber person, they can point you in the right direction.

I did it this way (cause its a stronger joint than just an angle bracket). I wouldnt tell you it has to be done this way. I was comfortable doing it, and i had the tools. Then drill holes through, and bolt them in place (1/4″ bolts from option #1 parts list)

Turn the whole thing on its side, and attach castors to the bottom at each corner.

Staple/Glue/Tack carpet along the top rail, and along the sides of the base. – I feel this might be optional. My wife wants it, so I will put it on.