Building A Camper Dolly: A Step-By-Step Guide

how to make a camper dolly

Building a camper dolly is a great way to make your camper more mobile and easier to store. Whether you're looking to move your camper around your garage or access other items stored in your space, a dolly can be a convenient and economical solution. In this guide, we'll explore the steps and materials needed to build your own camper dolly, taking into consideration weight capacity, wheel types, and construction methods. We'll also discuss the benefits and challenges of different designs, so you can create a sturdy and functional dolly tailored to your specific needs.

Characteristics Values
Materials 2 x 2-inch angle iron, 2 x 2-inch square metal tubing, 1.75 x 1.75-inch square metal tubing, 3 x 3-inch steel tube, plywood, castors, bolts, Cajun crawfish boiler, degreaser, distilled water, rust remover, black oxide, permeating oil, 2 x 6 lumber, 4 x 4 lumber, 4 x 8 trailer, 4" rubber casters, 8" x 2" wheels, metal screws, white Rustoleum, T-hooks, 1/2-inch round stock, paint
Dimensions 48 inches wide, 84 inches long, 4-foot by 9.5-foot platform, 4-foot by 5.5-foot bottom storage area, 6-inch wheels, 4-inch wheels, 20-inch height, 15-inch height, 2500-lb capacity
Weight 4,000 lbs, 1,500 lbs, 3,000 lbs
Cost $100, $200, $1,095
Time 2 days, 30-40 hours
Ease Difficult, extremely hard

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Choosing the right casters for your surface

When choosing casters for your camper dolly, it's important to consider the type of surface you'll be working with, as well as the weight of your camper. Here are some factors to keep in mind:

Weight Capacity

First and foremost, ensure that your casters can handle the weight of your camper. For heavier campers, consider casters with a weight capacity of at least 300 lbs each, or opt for a dolly with multiple casters to distribute the weight evenly.

Surface Type

The type of surface you'll be moving your camper on is crucial when selecting casters. For smooth, polished surfaces like concrete or asphalt, smaller solid casters or swivel casters will do the trick. If your surface has cracks or is made of gravel, larger wheels with pneumatic tires are recommended for better maneuverability.

Number of Casters

The number of casters you choose depends on the weight of your camper and the type of surface. For heavier campers, four swivel casters will provide better weight distribution and easier steering. For lighter campers, you can get away with two fixed and two swivel casters or even two fixed and four swivel casters for added stability.

Caster Size

Larger caster wheels are generally easier to push and can handle uneven surfaces better. If you're working with a rough or outdoor surface, consider pneumatic casters or caster wheels with a diameter of at least 6 inches. For indoor use, smaller caster wheels will suffice, but keep in mind that the larger the wheel, the easier it is to push and maneuver.

Caster Material

The material of your caster wheels is also important, as it needs to be durable enough for the surface you're working on. Polyurethane tires chemically bonded to an iron center tend to offer better service and are less prone to rusting than plastic alternatives. For high-humidity areas, consider treating the metal components with black oxide to prevent rusting.

Caster Specialists

When shopping for casters, consider using specialized websites like CasterCity.com or CasterSpecialists.com, which offer a wide range of options and competitive prices. You can also find casters at hardware stores like Home Depot or online retailers like Harbor Freight, which offer affordable options for lighter campers.

Remember to take into account the weight of your camper, the type of surface you'll be working on, and the level of maneuverability you require when selecting casters for your camper dolly.

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Building a stable platform

Planning and Materials

Start by measuring the base of your camper to determine the dimensions of the platform. It is essential to make the platform slightly wider and longer than the camper's base to provide full support. The platform should be constructed using sturdy materials such as plywood or metal tubing. For example, one builder used 3/4-inch plywood for the deck and a 3x3-inch steel tube frame.

Structural Design

When designing the structure of the platform, it is crucial to consider weight distribution and stability. One effective approach is to build the platform like a wall, using 2x6 "studs" running the length of the camper, spaced roughly 16 inches apart. These can be thought of as floor joists, providing support and distributing the weight evenly. Additionally, consider using a sheet of 1/2-inch OSB (oriented strand board) as the base to provide shear strength and enhance the platform's load-bearing capacity.

Caster Wheels

The caster wheels play a vital role in the stability and manoeuvrability of the dolly. It is recommended to use high-quality, heavy-duty caster wheels with a load rating that exceeds the weight of your camper. For example, if your camper weighs 4,000 pounds, each caster should have a load rating of over 1,000 pounds. Consider using larger diameter wheels, as they tend to be easier to push and manoeuvre over cracks or uneven surfaces. Additionally, you can opt for a combination of fixed and swivel casters for better control and stability.

Rust Prevention

If you live in an area with high humidity, consider taking extra steps to prevent rust on the metal components of your dolly. One builder suggests using black oxide on the metal tubing and following a thorough cleaning and rust removal process. This includes boiling the metal components in a degreaser, rinsing them in distilled water, and then soaking them in a rust remover solution overnight.

Additional Features

Depending on your specific needs, you may want to incorporate additional features into your dolly design. For example, you can add a handle to make it easier to manoeuvre the dolly, or include storage space for camper accessories, tie-downs, or a tonneau cover.

Remember to always work within your skill level and seek professional advice if needed. Building a stable platform for your camper dolly is a challenging but rewarding project that will make storing and moving your camper much more manageable.

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Using the correct materials

When making a camper dolly, it is important to use the correct materials to ensure it is sturdy and safe for use. The type of materials you will need will depend on the weight of your camper and the surface you will be moving it on.

For a dolly that can support a camper weighing around 1,500 lbs, you can use casters with a load rating of over 1,000 lbs, which can be found at hardware stores like Home Depot. If you need to support more weight, you can find casters with a higher load rating online. For example, casters with an 800 lb load rating each can be used to support a camper weighing 4,000 lbs.

The type of wheels you use will also depend on the surface you will be moving your camper on. For a concrete surface, swivel casters can be used, but they may need to be locked into side-to-side movement for easier manoeuvring. For a gravel driveway, larger-diameter pneumatic tires that are axle-mounted like a wagon are recommended. These will need to be at least 6 inches in diameter, with bigger wheels making it easier to push and move over cracks.

The frame of the dolly can be made from steel tubing, such as 3x3-inch or 2x2-inch square metal tubing, or 2x6 lumber. The size of the tubing or lumber will depend on the weight of your camper. For a camper weighing around 3,000 lbs, 3x3-inch steel tubing can be used. For a lighter camper, 2x2-inch tubing or 2x6 lumber can be used.

To attach the casters to the frame, you will need to weld them in place. This can be done by cleaning the metal with a degreaser and rust remover, then coating it with black oxide to prevent rusting, especially if you live in a high-humidity area. Once the frame is welded together, it can be painted to protect the metal and improve its appearance.

The platform of the dolly can be made from 3/4-inch plywood, with a base that is slightly larger than the base of your camper. This will provide a stable surface to support the weight of your camper.

By using the correct materials and considering the weight of your camper and the surface you will be moving it on, you can build a sturdy and safe camper dolly.

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Adjusting for height

For a gravel driveway, larger-diameter pneumatic tires that are axle-mounted like a wagon are recommended. These wheels provide better manoeuvrability and stability on uneven surfaces. Smaller wheels may struggle on gravel and other rough terrains. If your camper is on the heavier side, consider using wheels with a higher weight rating to ensure they can bear the load.

The height of the dolly can also be adjusted by altering the length of the legs. One user welded a frame with adjustable legs, allowing for 10 inches of height adjustment. This feature is especially useful if you need to accommodate different camper sizes or clear obstacles like lips or bumps on the floor.

Additionally, the height of the camper itself can be adjusted by lowering or raising the jacks. Ensure that the dolly's height, including the wheels, does not exceed the minimum height of the camper's jacks to avoid instability.

When designing the dolly, consider the clearance needed for the wheels. If space is limited, opt for smaller wheels to ensure they fit without obstruction.

Finally, the surface on which the dolly will be used should be considered. Smaller casters may struggle on uneven surfaces, so opting for larger wheels can make it easier to push and manoeuvre the camper. If using swivel casters, adding a bolt to lock the wheels in place can make it easier to control the direction of movement.

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Making it multi-purpose

If you want to make your camper dolly multi-purpose, consider adding features that will allow it to store and move other items, such as your Torklift truck tie-downs, truck tonneau cover, and tailgate. You can achieve this by adding a set of removable or repositionable dolly wheels, allowing you to transform the dolly into an upright structure with a handle for easy movement. Additionally, you can incorporate flip-down arms lined with rubber to securely hold and protect items like the tailgate and tonneau cover.

Another way to make your camper dolly multi-purpose is to design it with a storage shelf or platform underneath. This can provide extra space for storing camper-related items and accessories, keeping them organised and easily accessible. Ensure that the overall design and dimensions of the dolly can accommodate the base of your camper while leaving enough room for storage.

When constructing the dolly, consider using materials that can withstand the elements, especially if you plan to use it outdoors. For example, if you live in an area with high humidity, you may need to treat the metal components with a rust remover and a black oxide solution to prevent rusting. Proper treatment and coating of the metal parts will ensure the longevity of your multi-purpose camper dolly.

Additionally, you can make your dolly suitable for different surfaces by choosing the right type of wheels. For concrete surfaces, swivel castors can provide ease of movement, but for gravel or dirt surfaces, larger-diameter pneumatic tires that are axle-mounted may be more appropriate. Keep in mind that the wheel size and type will impact how easily the dolly moves over cracks and uneven terrain.

Frequently asked questions

You will need a strong base, such as plywood, and wheels. For the base, you can use steel tubing or angle iron, and for the wheels, you can use casters or pneumatic tires, depending on the surface you'll be moving your camper on.

You can weld together steel tubing to create a frame that will fit your camper's dimensions. Alternatively, you can use lumber to create a base, similar to building a wall with studs.

If you live in an area with high humidity, you can use black oxide on the metal components to prevent rusting. You can also boil the metal parts in a degreaser, remove any remaining rust, and then soak them in a rust remover solution before rinsing and applying the black oxide.

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