Stand Up Paddleboard Handcart Trailer
by Prism Preston in Outside > Water
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Stand Up Paddleboard Handcart Trailer
Stand Up Paddleboard Cart
Is This Cart for YOU?
1. Live about 1 mile or less from a lake or ocean!
2. Need a way to pull your 3 Stand Up Paddleboards, kayaks, or a bunch of beach chairs, or anything under 100pounds!
3. Don’t have a welder and want to build this with “off the shelf” products from your local hardware store!
4. Need a way to easily store and move your SUP’s while not using them!
If you answered YES to the above, this simple cart is for you! Keep on scrolling down!!
2. Need a way to pull your 3 Stand Up Paddleboards, kayaks, or a bunch of beach chairs, or anything under 100pounds!
3. Don’t have a welder and want to build this with “off the shelf” products from your local hardware store!
4. Need a way to easily store and move your SUP’s while not using them!
If you answered YES to the above, this simple cart is for you! Keep on scrolling down!!
What You Will Need!
MAIN TRAILER FRAME:
This cart design and measurements is based around a kids Instep 2 seater bike trailer. See “Step 8 Notes” below why!
Confirm OUTSIDE dimensions of the Instep trailer frame are 26 inch wide by 31.5 inch long. These trailers are common on Facebook Marketplace and Craigslist and sell for between $25-$150.
This trailer was left in the sun and the seatbelt harness and fabric dry rotted so I got it for $25.
****Make sure your trailer has the “stroller” option which includes the rear wheel brake and front swivel wheel when you buy.
All tools and materials below I bought at Home Depot**
TOOLS:
-Two adjustable wrenches
-Tape measure
-Pencil
-Drill with 3/8” bit
-PVC cutter, this makes cutting pvc cuts precise and easy! (https://www.homedepot.com/p/Husky-1-1-4-in-Ratcheting-PVC-Cutter-16PL0101-1/304217581)
MATERIALS-
3 - 10 foot piece of 1inch SCH40 PVC pipe
8 - 1 inch PVC 90deg Elbows
8 - 1 inch PVC Tee
4 - 1 inch PVC Side Outlet 90-Degree Socket Elbow
2 - 3/8 in. x 4 in. Zinc-Plated Eye Bolt with Nut
2 - Everbilt 5/16 in. x 1-3/8 in. x 2-1/2 in. Coarse Zinc-Plated U-Bolt
2 - 48 inch bungee cords
1 - Can of light colored spray paint to paint PVC
1 - 6 foot stick of steel. 1inch outside diameter, 1/8inch wall thickness
1 - Pack of 11” nylon white zip ties
1 - PVC cement. (I didn’t use primer, I feel the joints are plenty strong without the extra step, but you may)
This cart design and measurements is based around a kids Instep 2 seater bike trailer. See “Step 8 Notes” below why!
Confirm OUTSIDE dimensions of the Instep trailer frame are 26 inch wide by 31.5 inch long. These trailers are common on Facebook Marketplace and Craigslist and sell for between $25-$150.
This trailer was left in the sun and the seatbelt harness and fabric dry rotted so I got it for $25.
****Make sure your trailer has the “stroller” option which includes the rear wheel brake and front swivel wheel when you buy.
All tools and materials below I bought at Home Depot**
TOOLS:
-Two adjustable wrenches
-Tape measure
-Pencil
-Drill with 3/8” bit
-PVC cutter, this makes cutting pvc cuts precise and easy! (https://www.homedepot.com/p/Husky-1-1-4-in-Ratcheting-PVC-Cutter-16PL0101-1/304217581)
MATERIALS-
3 - 10 foot piece of 1inch SCH40 PVC pipe
8 - 1 inch PVC 90deg Elbows
8 - 1 inch PVC Tee
4 - 1 inch PVC Side Outlet 90-Degree Socket Elbow
2 - 3/8 in. x 4 in. Zinc-Plated Eye Bolt with Nut
2 - Everbilt 5/16 in. x 1-3/8 in. x 2-1/2 in. Coarse Zinc-Plated U-Bolt
2 - 48 inch bungee cords
1 - Can of light colored spray paint to paint PVC
1 - 6 foot stick of steel. 1inch outside diameter, 1/8inch wall thickness
1 - Pack of 11” nylon white zip ties
1 - PVC cement. (I didn’t use primer, I feel the joints are plenty strong without the extra step, but you may)
Dismantling the Instep Trailer.
Remove the fabric canopy by unbuckling or cutting the straps that hold the fabric to the metal frame. There is also 6 Phillips screws that hold the fabric on at all corners, unscrew these.
Remove the push bar if there is one.
Turn the cart over:
-Remove the two screws holding the bar between the wheel brakes. Gently pry 2 plastic brakes apart and bar can be removed.
-Remove the roll cage. There are 4 bolts, 2 on either side.
Remove the push bar if there is one.
Turn the cart over:
-Remove the two screws holding the bar between the wheel brakes. Gently pry 2 plastic brakes apart and bar can be removed.
-Remove the roll cage. There are 4 bolts, 2 on either side.
Cutting the PVC to Length.
Use the diagram above to cut your PVC pieces to the correct length. As you can see, the dimensions on either side are symmetrical.
NOTE- The measurements in the picture are the total length of each piece of pipe. There will be “makeup” loss when the pipes are assembled. For 1inch PVC pipe, each connection will require 7/8inch to insert into the connection and fully seat into the connection. So, if you have two connections on either side, the makeup loss will be 1.5 inches total.
Since you have the PVC cutting scissors, I found it easy to cut the pieces as I go so I do not mix up measurements. If you choose to cut all pieces, be sure to write the dimension on each length of pipe!
NOTE- The measurements in the picture are the total length of each piece of pipe. There will be “makeup” loss when the pipes are assembled. For 1inch PVC pipe, each connection will require 7/8inch to insert into the connection and fully seat into the connection. So, if you have two connections on either side, the makeup loss will be 1.5 inches total.
Since you have the PVC cutting scissors, I found it easy to cut the pieces as I go so I do not mix up measurements. If you choose to cut all pieces, be sure to write the dimension on each length of pipe!
Gluing and Assembly.
It is easiest to put this up on a large flat table so you don’t have to work on your hands and knees!
Also, remove the wheels like in the picture so the trailer sits flat on the table.
IMPORTANT - For gluing tips and tricks see “Step 8: Notes” below.
I started at the back of the cart.
Starting at the back, once you have glued the two corner pieces(Side outlet 90 degree connections) onto the 21.5 inch piece of pipe, this will determine the width for the PVC rack project (see red arrows in first picture.) Use this rear section with the corner connections as a gauge when gluing together the other 3 assemblies of pipe that will go across the trailer.
I would make the 4 sub-assemblies that go across the trailer first. HINT: When I was ready to glue the last pipe connection and finish a sub-assembly, I would hold the assembly against the rear PVC assembly to make sure the Front and two middle sub-assemblies match the same width.
With the 4 sub-assemblies glued together, these can then be connected progressing toward the front of the trailer.
***To ensure the joints that hold the uprights are vertical, I suggest cutting a 20.5inch section of pipe and lightly pressing it into the “tee” connection before gluing. Then when you glue and make up the connection joint, you can truly see the pipe is vertical. It’s hard to gauge if a connection is orientated correct otherwise.
NOTE:
To make two connections line up, or orientate correctly, like the two “Side Outlet 90 degree” connections on the back corners, if you add glue to the pipe and one connection then insert them together, let dry for 30 seconds. Then glue and add the other connection and quickly set the assembly resting on the bottoms of the corner connections, this will ensure the two connections are orientated correctly to one another.
Also, remove the wheels like in the picture so the trailer sits flat on the table.
IMPORTANT - For gluing tips and tricks see “Step 8: Notes” below.
I started at the back of the cart.
Starting at the back, once you have glued the two corner pieces(Side outlet 90 degree connections) onto the 21.5 inch piece of pipe, this will determine the width for the PVC rack project (see red arrows in first picture.) Use this rear section with the corner connections as a gauge when gluing together the other 3 assemblies of pipe that will go across the trailer.
I would make the 4 sub-assemblies that go across the trailer first. HINT: When I was ready to glue the last pipe connection and finish a sub-assembly, I would hold the assembly against the rear PVC assembly to make sure the Front and two middle sub-assemblies match the same width.
With the 4 sub-assemblies glued together, these can then be connected progressing toward the front of the trailer.
***To ensure the joints that hold the uprights are vertical, I suggest cutting a 20.5inch section of pipe and lightly pressing it into the “tee” connection before gluing. Then when you glue and make up the connection joint, you can truly see the pipe is vertical. It’s hard to gauge if a connection is orientated correct otherwise.
NOTE:
To make two connections line up, or orientate correctly, like the two “Side Outlet 90 degree” connections on the back corners, if you add glue to the pipe and one connection then insert them together, let dry for 30 seconds. Then glue and add the other connection and quickly set the assembly resting on the bottoms of the corner connections, this will ensure the two connections are orientated correctly to one another.
Adding the Pull Bar and Hardware.
My “manager” demanded to step in and grab a wrench! Average length SUP board is 11.5feet. So, I didn’t cut the 6 foot piece. If you have longer or shorter boards, you can adjust accordingly. It’s best and easiest to wipe down the stick of metal with iso-alcohol and paint before mounting to the trailer. I added some orange stripes so people can see the pipe end and not walk into it with their shin, ouch...I did it many times before I thought to add these stripes.
The “U” bolts fit snug and best to alternate one up and one down to spread the load. If you would like to paint the trailer at this time you may, but I found the original baked on paint to be very durable and in good condition. I’m not sure what to add as a handle yet, maybe a bicycle grip or some athletic tape, but I’ll use it a few times and determine what would feel best and last with the ocean water.
You will also install the 2 metal Eyelets now, which can be seen in the picture above. Drill a 3/8” hole in the bottom of the Tee connection in the middle of the PVC frame. You can use the front or rear connections, either will work. Insert the eyelet and makeup the nut on the bottom. Tighten until the top of the PVC connection starts to flex. I used an extra nut to act like a locknut so it does not come undone. I don’t find this necessary looking back.
The “U” bolts fit snug and best to alternate one up and one down to spread the load. If you would like to paint the trailer at this time you may, but I found the original baked on paint to be very durable and in good condition. I’m not sure what to add as a handle yet, maybe a bicycle grip or some athletic tape, but I’ll use it a few times and determine what would feel best and last with the ocean water.
You will also install the 2 metal Eyelets now, which can be seen in the picture above. Drill a 3/8” hole in the bottom of the Tee connection in the middle of the PVC frame. You can use the front or rear connections, either will work. Insert the eyelet and makeup the nut on the bottom. Tighten until the top of the PVC connection starts to flex. I used an extra nut to act like a locknut so it does not come undone. I don’t find this necessary looking back.
Painting and Finishing Touches.
I just painted the PVC, as I said, the trailer paint was in good shape and why disturb what is already good?
No need to paint the PVC, but if you do, I suggest painting the PVC something light colored since it will be in the sun a lot and will fade over time. I used Modern Mint.
I also painted the ends of the wheel brakes so they are easy to identify and other people can be instructed to engage or release the two “orange” brake levers.
After painting, its time to Zip tie it on! One could bolt it on but zip ties seem to be more flexible in case the PVC is not exactly square.
Try to get the PVC rack centered on the trailer. You might need to rotate the “U” bolt slightly to allow enough room. I used two on either side of connections and a few in the back. Each zip tie holds 50lbs, so it is not going anywhere with a dozen ties!
For the bungee cords, if you find the center of the cord, tie it around the top rail inline with your eyelet, this makes it nice so you don’t lose the bungee cords. Depending on your board width, you might need longer or shorter cords. Once you put your board on, you can pull a strap over the board and hook it on the eyelet.
Always tiedown the boards in the vertical position. This decreases the force on the uprights so they will not break.
No need to paint the PVC, but if you do, I suggest painting the PVC something light colored since it will be in the sun a lot and will fade over time. I used Modern Mint.
I also painted the ends of the wheel brakes so they are easy to identify and other people can be instructed to engage or release the two “orange” brake levers.
After painting, its time to Zip tie it on! One could bolt it on but zip ties seem to be more flexible in case the PVC is not exactly square.
Try to get the PVC rack centered on the trailer. You might need to rotate the “U” bolt slightly to allow enough room. I used two on either side of connections and a few in the back. Each zip tie holds 50lbs, so it is not going anywhere with a dozen ties!
For the bungee cords, if you find the center of the cord, tie it around the top rail inline with your eyelet, this makes it nice so you don’t lose the bungee cords. Depending on your board width, you might need longer or shorter cords. Once you put your board on, you can pull a strap over the board and hook it on the eyelet.
Always tiedown the boards in the vertical position. This decreases the force on the uprights so they will not break.
NOTES AND AFTER THOUGHTS.
Instep Kids Bike Trailer:
**WHEN PURCHASING MAKE SURE YOU GET THE STROLLER ADDITIONS**which include the front swivel wheel and rear tire brakes.
I chose this trailer for many reasons:
1. It’s easy to find used ones and repurpose, so decreasing what goes to the land fill! The fabric dry rots or the harnesses break eventually and that is the end of the critical safety part of the trailer, and not worth investing, if you can even find, the replacement canopy and straps.
2. The wheels are plastic and salty ocean water will not corrode them like aluminum or steel wheels. I filled my tires with Slim so I never have to pump them up again! Also I run the tires a little low to help float on the sand.
3. The small spin wheel on the front is so awesome for stabilizing the trailer while not in use. My carbon fiber boards never have to touch the ground like many other SUP hauling devices. It is also very nice for moving around, it turns on a dime.
4. You can just leave your boards on the rack for storage in the garage or in your side yard.
5. I just bought another replacement trailer for my girls and plan to use this design to repurpose the trailer when the girls no longer want to ride in the trailer
Site:
https://www.amazon.com/Instep-Quick-Double-Trailer-Green/dp/B01N5SZDEM/ref=sr_1_2_sspa?dchild=1&keywords=Instep+Bike+Trailer&qid=1629468479&sr=8-2-spons&psc=1&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUExSDQxUDVZUjlUNzZZJmVuY3J5cHRlZElkPUEwNzU3OTgwM09ZMkU2TDJTV1Q4OCZlbmNyeXB0ZWRBZElkPUEwOTI5NTQyMVVFR1hGUDFRNVFFRiZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU=
PVC GLUING TIPS and Tricks:
Make sure you fully seat each connection when gluing. Dimensions will be off if not done so. After gluing the pipe and inside of the connection, push the pipe together and HOLD IT for 10 seconds. If you push the pipe in and let go, hydraulic pressure will spit the pipe out and dimensions will be all whacked!
OPTIONAL: ADAPTING FOR KAYAKS:
By changing the PVC uprights of the cart, this can be transformed in a two tier cart for hauling Kayaks. Instead of the supports going length wise with the trailer, have them go across the trailer, then you can have a lower shelf and upper shelf for kayaks to rest on.
Loading and Hauling Boards:
Depending on the length of your boards, you’ll want to set them in the cart differently. I was able to put my boards about a foot behind center so there was less weight to carry with my hand, any farther back and the board tails would hit the ground. So play with forward or back when mounting to get the balance that works best for you and your boards.
**WHEN PURCHASING MAKE SURE YOU GET THE STROLLER ADDITIONS**which include the front swivel wheel and rear tire brakes.
I chose this trailer for many reasons:
1. It’s easy to find used ones and repurpose, so decreasing what goes to the land fill! The fabric dry rots or the harnesses break eventually and that is the end of the critical safety part of the trailer, and not worth investing, if you can even find, the replacement canopy and straps.
2. The wheels are plastic and salty ocean water will not corrode them like aluminum or steel wheels. I filled my tires with Slim so I never have to pump them up again! Also I run the tires a little low to help float on the sand.
3. The small spin wheel on the front is so awesome for stabilizing the trailer while not in use. My carbon fiber boards never have to touch the ground like many other SUP hauling devices. It is also very nice for moving around, it turns on a dime.
4. You can just leave your boards on the rack for storage in the garage or in your side yard.
5. I just bought another replacement trailer for my girls and plan to use this design to repurpose the trailer when the girls no longer want to ride in the trailer
Site:
https://www.amazon.com/Instep-Quick-Double-Trailer-Green/dp/B01N5SZDEM/ref=sr_1_2_sspa?dchild=1&keywords=Instep+Bike+Trailer&qid=1629468479&sr=8-2-spons&psc=1&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUExSDQxUDVZUjlUNzZZJmVuY3J5cHRlZElkPUEwNzU3OTgwM09ZMkU2TDJTV1Q4OCZlbmNyeXB0ZWRBZElkPUEwOTI5NTQyMVVFR1hGUDFRNVFFRiZ3aWRnZXROYW1lPXNwX2F0ZiZhY3Rpb249Y2xpY2tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU=
PVC GLUING TIPS and Tricks:
Make sure you fully seat each connection when gluing. Dimensions will be off if not done so. After gluing the pipe and inside of the connection, push the pipe together and HOLD IT for 10 seconds. If you push the pipe in and let go, hydraulic pressure will spit the pipe out and dimensions will be all whacked!
OPTIONAL: ADAPTING FOR KAYAKS:
By changing the PVC uprights of the cart, this can be transformed in a two tier cart for hauling Kayaks. Instead of the supports going length wise with the trailer, have them go across the trailer, then you can have a lower shelf and upper shelf for kayaks to rest on.
Loading and Hauling Boards:
Depending on the length of your boards, you’ll want to set them in the cart differently. I was able to put my boards about a foot behind center so there was less weight to carry with my hand, any farther back and the board tails would hit the ground. So play with forward or back when mounting to get the balance that works best for you and your boards.
AND.... Thank You for Reading and Becoming a Builder!
You have repurpose a stroller/trailer that would have gone to the dump, well done. For posterity reasons, I love this! Grab a friend, or your kid, and have fun building! PVC is a great media for creating. After this project you will have gained a lot of basic knowledge of how to measure, glue, and build with PVC!
COST and TIME:
This projects cost me about $125. $25 for the trailer, and $100 for materials and the new PVC cutting tool. It took me 4 hours to build with another hour of painting/drying time.
COST and TIME:
This projects cost me about $125. $25 for the trailer, and $100 for materials and the new PVC cutting tool. It took me 4 hours to build with another hour of painting/drying time.