Building A Pickup Camper Dolly: A Comprehensive Guide

how to make pickup camper dolly

Building a pickup camper dolly is a great way to make your camper more mobile and accessible. Whether you're looking to move your camper around your garage or store it against a wall, a dolly can be a useful solution. In this guide, we'll explore the steps and materials needed to create a sturdy and functional dolly for your pickup camper. From welding a steel tube frame to selecting the right casters, we'll cover everything you need to know to build a safe and effective dolly for your camper.

Characteristics Values
Dolly type Trolley, wheeled platform, car wheel dolly, trailer
Dolly material Steel, plywood, lumber, aluminium
Dolly dimensions 4-foot by 9.5-foot platform, 4-foot by 5.5-foot storage area
Wheel type Swivel, fixed, pneumatic, high capacity, small
Number of wheels 4, 6
Wheel size 4", 8" x 2"
Wheel cost $16 each, $280 total
Dolly weight 3,000 lbs
Dolly cost $1,095
Dolly construction time 30-40 hours

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Using a steel tube frame, plywood deck, and castors

Building a pickup camper dolly with a steel tube frame, plywood deck, and castors can be a rewarding DIY project. Here's a step-by-step guide to help you get started:

Planning and Materials:

  • Determine the desired size of your dolly, considering the size of your camper and the space you'll be moving it in.
  • Gather your materials:
  • Steel tubes for the frame (length and thickness depending on your desired size)
  • Plywood sheet for the deck (e.g., 3/4-inch thick, at least 18x32 inches, or larger if needed)
  • Four swivel caster wheels with a load rating suitable for your camper's weight (consider larger wheels for easier manoeuvrability)
  • Wood screws (length suitable for the thickness of your plywood and wheel brackets)
  • Sandpaper (medium grit)
  • Optional: wood finish or paint, safety goggles, a handle or strap for manoeuvring

Construction:

  • Cut the steel tubes to the desired length for the frame. Consider a rectangular or square shape for stability.
  • Assemble the steel tube frame using strong welding techniques to ensure durability.
  • Cut the plywood sheet to size if needed, and sand down the edges to prevent splinters.
  • Place the plywood deck upside down on a flat surface.
  • Position the caster wheels near each corner of the plywood, ensuring even spacing. Mark the screw holes for each caster.
  • Put on safety goggles. Drill small pilot holes on the marks to prevent wood splitting when screwing in the wheels.
  • Align the caster wheels with the pilot holes and attach them securely using the wood screws. Ensure the wheels swivel smoothly.
  • Optional: apply a finish or paint to the plywood for a more durable and aesthetically pleasing result.
  • Turn the dolly right side up and test its functionality by placing your camper on it and pushing it around.

Tips and Considerations:

  • Choose swivel casters with brakes for added safety, especially when using the dolly on inclines.
  • Consider the weight distribution of your camper and select casters with an appropriate load rating.
  • Ensure your work area is well-lit and free from obstructions during the building process.
  • Always wear safety goggles when cutting or drilling.
  • Experiment with different materials, sizes, or features like shelving to customise your dolly further.

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Welding C-channel and tubing with dolly wheels

When welding C-channel and tubing with dolly wheels, it is important to consider the type of material you are working with and the specific application.

If you are using structural C-channel, which is typically made of mild steel and rolled in a mill, it can be welded in any direction without restriction. However, if the C-channel has been formed from flat material, it may be composed of unknown or low-alloy steels, and welding across the flanges should be avoided to prevent structural weakness.

When welding rectangular tubing or boxed C-channel, it is important to consider the load distribution and the areas of the beam that carry the most bending forces. For example, when reinforcing a travel trailer frame with C-channel, welding to the flanges will provide more support than welding to the neutral axis in the web area.

Additionally, the size and type of welds can impact the strength and appearance of the final product. Intermittent or stitch welds can be used to join two pieces of C-channel together, while filling the radius of rectangular tubing can provide additional support.

When working with thin-wall tubing, special care must be taken to avoid blowing holes. Using smaller wire sizes, lower voltage settings, and shorter welds can help prevent overheating and melting through the material.

Finally, consider the weight distribution and ease of manoeuvrability when designing the dolly. Larger wheels can make it easier to push and manoeuvre over cracks and uneven surfaces. Additionally, positioning the weight closer to the vertical centre of the dolly can improve stability and make it easier to navigate stairs or uneven terrain.

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Using a pre-made trailer

Choosing the Right Trailer

First, you'll need to select an appropriate trailer that can accommodate the weight and dimensions of your camper. Consider the weight capacity and ensure it can handle the tongue weight and gross weight of your camper trailer. Check if the trailer dolly is compatible with your trailer hitch. Rear receiver hitches are the most common and easiest to use. Also, consider the type of terrain you'll be using the dolly on and choose a trailer with appropriate tires and grip.

Modifying the Trailer

You can modify a pre-made trailer to better suit your needs. For example, you can add a wooden frame or box on top of the trailer to support and secure your camper. Pressure-treated lumber, such as PT 4x4 frames with PT 2x4 cross members or PT 2x6's sistered together, can provide a sturdy base. Consider adding a lip around the outside top of the frame to ensure the camper edges seat properly. You may also want to install tie-down hooks or use Torklift tie-downs for added stability.

Enhancing Maneuverability

To enhance the maneuverability of your pre-made trailer dolly, consider adding a trailer mover or dolly adapter. This will allow you to move your camper short distances without a truck, making it easier to position in your garage or camping space. Trailer dollies elevate the tongue of the trailer and provide a control handle for easy steering. They improve traction and reduce the amount of force needed to move your camper.

Safety Considerations

When using a pre-made trailer as a dolly, always prioritize safety. Ensure that your trailer has adequate brakes, especially if you'll be moving it over uneven or slanted terrain. When loading the trailer, pay attention to weight distribution. Keep plenty of weight on the hitch to prevent the tongue from jumping up when unlocking it from the car's hitch. Always be cautious and consider adding safety features such as a "dead man" switch or a breakaway cable for emergency stops.

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Bolting castors to jack feet

If you have a slanted driveway or any kind of lip or bump that the camper needs to get over, it is not advisable to bolt castors to jack feet. The sideways torque on the jack brackets can cause damage to the camper.

Instead, it is suggested to build a dolly for the camper, with a platform that has the exact dimensions of the base of the camper. This provides stability and makes it easier to manoeuvre the camper in tight spaces. The dolly can be built using 2x6 lumber, with casters attached to a 2x8 at both ends. The casters should be large enough to easily roll over any bumps or cracks in the surface.

When building a dolly, it is important to consider the weight of the camper and choose casters with an appropriate load rating. For a camper weighing around 1500lbs, casters with a load rating of over 1000lbs should be sufficient. For a heavier camper, higher-capacity casters may be required.

In summary, while bolting castors to jack feet may be possible, it is not recommended due to the risk of damage to the camper. Building a dolly with appropriately sized and rated casters is a safer and more effective method for moving a camper around in a garage or on uneven surfaces.

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Using a load-divider dolly

A load-divider dolly is a device that can be used to make your half-ton truck safe and legal when you need to move a lot of weight. It is especially useful for those who only occasionally need to exceed their truck's gross vehicle weight rating (GVWR). For example, farmers whose half-ton trucks are sufficient except when transporting harvested crops, or vacationers with heavy pickup-bed campers.

The load-divider dolly is equipped with three air springs and connects to a truck's Class-III hitch receiver, allowing it to serve as an additional loaded axle with passive steering. Two air springs support the axle and shoulder some of the rear axle's burden, while a third imparts a torque moment between the hitch receiver and the trailer, shifting some payload burden to the front axle. This helps to optimise load distribution, improving safety and control, and reducing brake, tire, and suspension wear.

When creating a load-divider dolly, it is important to consider the weight capacity and height of the dolly, as well as the size and type of casters or wheels used. For a heavier camper, such as one weighing 4,000 lbs, it is recommended to use casters with a high load rating, such as those available from Caster Specialists. Additionally, larger-diameter wheels can make it easier to push the dolly and manoeuvre over cracks in the floor.

In terms of caster configuration, you can choose between having two castering wheels and two fixed wheels, or four castering wheels. If you're dealing with a heavier load, it's recommended to have two fixed wheels and some amount of swivel wheels to make it easier to control and manoeuvre, especially if you'll be navigating around obstacles in your garage.

Frequently asked questions

You will need heavy-duty castors, a steel tube frame, plywood, paint, and self-tapping metal screws.

First, weld a steel tube frame to carry the weight of the camper. Then, attach a plywood deck to the frame using self-tapping metal screws. Paint the dolly, and add castors to the bottom.

Consider the weight of your camper, and choose castors with a high enough load rating. Bigger wheels are also easier to push and manoeuvre over uneven surfaces.

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