I typed up a long post last night; but naturally, I got one of those “database errors” that happen all the time since the message board was changed. Anyway…
I don’t have a garage (yet) or a proper workspace. My dad’s drill press is down in San Diego, and the platform would be too unwieldy anyway. I got a Lowe’s gift card for Christmas, so I bought a 12v Black & Decker drill and some bits. Then I went to Sears. I was hoping to find a “Portalign”*, but they seem not to exist anymore. I ended up getting a miniature Crafstman drill press.
I drew parallel lines 31cm from the centreline on each side. That’s where the wheels go. It was awkward drilling the holes with the mini-drill press, but it was the best I could do. The places I wanted to drill were close to the edge of the platform, and the base of the press wouldn’t fit on the it. I used a metal ruler to level it. I managed to drill 17 holes successfully. There should only have been 16 holes, but I drilled into a false mark. After drilling the first four (well, five :o ) holes, it was time to try the wheels.
Oops. I’d forgotten about the 1/2" deep piece of channel aluminum that holds the trucks. My bolts were too short. I went down to the hardware store and got new ones. While I was there, I picked up two 10-foot lengths of 1-1/2", schedule 40, ABS pipe to use as tracks.
The wheels went on nicely. And whaddya know! The dolly runs very well and very quietly on the track!
But about those bolts… I don’t really like the nuts protruding from the surface of the platform. I think I’ll go back and get the shorter bolts and contersink the holes in the top of the platform 1/2 inch.
Now I need to sand the edges of the platform. The guy who cut the plywood was not very accurate, and one edge is 1/4" too wide at one end. This is a heavy piece of wood; and, as I said, I don’t have a proper means of supporting it and making it true. Or do I…? I have a little Craftsman disc/belt sander. I have a platform with wheels on it, and track. It’s supposed to rain today; but I’ll bet I can put the sander on the deck when it’s dry, and set up the dolly and track next to it. Then I can move the dolly across the disc. That should work. I’ll also have to dig out a depression in the middle of the platform so I can flush-mount a ring pull.
A quart of grey wing walk compound (non-skid stuff) is on its way from Sporty’s Pilot Shop. I have a quart of spar varnish. After I sand the platform and mount the ring, I’ll remove the hardware and apply the spar varnish to protect the wood from this wet environment. Next I’ll apply the wing walk compound to the top. After the wheels and ring pull are put back on, there’s only one more thing I need.
The push handles. There are various handles I can make: PVC, iron pipe, one upright, two uprights… But I want this to look good as well as to be functional. I need to find someone who can weld an aluminum handle for me. I want two uprights with a crossmember 2 inches from the bottom. I’ll bore holes in the platform to accept the uprights, and the crossmember will hold it in place. I’ll have a longer crossmember on the top, to which I’ll attach handgrips. If I’m really feeling tricky, I’ll get some plumbing fixtures (1-1/2" long metal pipe with a little flare on one end) to line the holes.
A skateboard dolly like this costs about $600 if you just go out and buy it. Mine will end up being about $250. I did buy some tools, but I’ll use those for other projects so they don’t really count as part of the cost of the dolly. I could have gotten off cheaper if I had built the trucks from scratch, but I didn’t want to mess with it this time.
*[sub]A Portalign is a disc about 4" in diameter with a large hole in the middle. The disc has two vertical rods on it. There is a “butterfly” device that fits onto your hand drill. It’s a pair of tubes with an aluminum web that joins them. These tubes fit over the vertical rods, allowing the drill to be moved up and down perpendicular to the object being drilled. That is, a Portalign is a handheld drill press. [/sub]