Fabrication set

Finished · front of the design
Sheet 6 of 6
Cut list
Aluminum frame and thin plywood, so one person can push it across a lot. Hitch it for a hill. Buy the pneumatic wheels and the solar module first.
| Mark | Qty | Part | Material | Size, mm |
|---|---|---|---|---|
| A | 2 | Lower side rail | 6061-T6 aluminum | 50 × 50 × 3 × 1580 |
| B | 2 | Lower cross rail | 6061-T6 aluminum | 50 × 50 × 3 × 560 |
| C | 4 | Deck post | 6061-T6 aluminum | 40 × 40 × 3 × 296 |
| D | 4 | Roof post | Aluminum tube | 32 OD × 3 wall × 736 |
| E | 2 | Axle | Steel spindle | Ø16 × 900, match the hub |
| F | 1 | Kingpin | Steel | Ø20 × 80, handle-end axle |
| G | 4 | Wheel | Pneumatic | 400 OD × 70, light hub, 16 mm bore |
| H | 1 | Deck | Exterior plywood | 1660 × 780 × 12 |
| J | 2 | Long panel | Exterior plywood | 1700 × 255 × 12 |
| K | 2 | End panel | Exterior plywood | 780 × 255 × 12 |
| L | 1 | Roof | Exterior plywood | 1820 × 960 × 6 |
| M | 1 | Sign box | Thin cedar, acrylic face | 1460 × 400 × 60, 3 mm face |
| N | 1 | PV module | 200 W | 1320 × 670 × 35, 36° facing south |
| P | 1 | Charge controller | MPPT 10 A | 12 V, in the battery box |
| Q | 1 | Battery | LiFePO4 | 12 V, 40 Ah, 480 Wh |
| R | 1 | Battery box | Sealed, fused | 320 × 180 × 160 |
| S | 1 | Cash box | Steel, keyed | 260 × 140 × 100, slot 110 × 12 |
| T | 1 | Tap shelf | Aluminum | 180 × 240 face, 34° up |
| U | 2 | Handle upright | Aluminum tube | Ø32 × 550 |
| V | 1 | Handle grip | Aluminum tube | Ø32 × 500 |
| W | 2 | Tongue rail | 6061-T6 aluminum | 50 × 50 × 3, about 1600 long |
| X | 1 | Coupler | 2 inch ball | Rated 900 kg, latch and lock |
| Y | 1 | Tongue jack | Swivel | 450 kg, wheel, stows up |
| Z | 2 | Safety chain | Grade 30 or better | Crossed, clevis hooks, from the frame |
| AA | 3 | Hitch pin | Steel | Ø16, hairpin clips, two for the tongue, one locks the kingpin |
| AB | 1 | Lamp set | LED, 12 V | Tail, stop, turn, plate lamp, amber and red markers |
| AC | 1 | Harness | 4-pin flat | White ground, brown tail, yellow left, green right |
Notes for the shop
- Units are millimetres. Print A3 landscape at 100% so the views stay 1:12.
- Do not scale a fitted PDF. If a dimension and the graphic disagree, the dimension wins.
- Frame, posts, handle, and tongue are 6061-T6 aluminum, not steel. TIG weld with 5356 filler. If the shop cannot weld aluminum, bolt the joints with stainless brackets.
- Where aluminum meets the steel axles, coupler, or cash box, tape the joint. Victoria rain will pit bare aluminum against steel.
- Skin is 12 mm exterior plywood. The roof is 6 mm. Seal every edge. Do not use 19 mm sheet or a steel frame. That is what makes it too heavy to push.
- Wheels are 400 mm pneumatic with light hubs, not steel wagon wheels. They roll across a parking lot and over a curb lip.
- Battery is lithium, about 5 kg. Do not fit a lead-acid battery.
- Empty, the cart is about 90 kg. With the day's buckets, about 120 kg. That is an estimate. Weigh it before you plate it.
- In a parking lot, pull the tongue off and push from the handle. The near axle steers. On a hill or a road, hitch it and tow. Do not push a loaded cart up a grade.
- Handle-end axle steers for pushing. Before towing, lock that kingpin so the axle cannot pivot.
- The tongue is removable. Two pins hold the A-frame to the lower frame. Take it off at the curb so it does not stick into the sidewalk.
- Coupler is a 2 inch ball, about 430 mm off the ground when the cart is level. Latch it and pin the latch.
- Cross the safety chains under the tongue. They attach to the frame, not only to the coupler.
- Four tires stay on the road, so they scrub in a tight turn. Take the turn wide.
- Put about 15 to 25 kg on the ball. If the tongue lifts, shift buckets toward the hitch.
- Lights are required on a B.C. road: tail, brake, turn, plate lamp, and side markers. Plug the 4-pin into the vehicle and check them before you move.
- Brakes are not drawn. B.C. requires them if the loaded trailer is over 1 400 kg, or over half the weight of the tow vehicle. This cart should stay well under that. Confirm the loaded weight.
- Register and plate it with ICBC before it goes on a public road. This drawing is not a certification, a VIN, or an inspection.
- Sign is a gasketed lightbox, 12 V LED, about 24 W. Acrylic face, printed vinyl behind it.
- Panel, controller, and battery are 12 V. Fuse the panel at 10 A and the battery feed at 20 A. Reader on its own 3 A fuse.
- Bond the module frame and the aluminum cart to battery negative. Use outdoor cable and drip loops.
- Cash box is mechanical. It does not need power. Bolt it through the front panel.
- Confirm the module hole pattern and the wheel bore before drilling.
- Victoria street vending needs a city permit. This drawing is the cart, not the permit.