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Type I Bug Body Dolly (cart) build plans
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slave1pilot
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PostPosted: Sat Feb 09, 2019 3:01 pm    Post subject: Type I Bug Body Dolly (cart) build plans Reply with quote

I searched a bit for some plans to build a dolly to put the body on when I separated it from the pan, but didn't find what I needed.
so, I built my own and decided I would start a new thread with an easily searchable title.
This is what I built:
Image may have been reduced in size. Click image to view fullscreen.

THIS CART/DOLLY IS THE SHORT VERSION THAT GOES UNDER THE CABIN<NOT THE FRONT AND REAR APRONS
Like so:
Image may have been reduced in size. Click image to view fullscreen.


Here are the materials I bought and current prices from Home Depot
(I'm using pics instead of links so the info doesn't disappear)
Image may have been reduced in size. Click image to view fullscreen.


I also purchased these 5" locking swivel casters from Amazon
Image may have been reduced in size. Click image to view fullscreen.


Please feel free to upgrade any or all parts as you see fit, this is just what worked for me personally.

I measured my bug completely stripped down with engine,interior,and all body parts removed.
The front beam was the highest point at just under 27", and the tires were right at 61" wide (with incorrect sized tires.)
I figured that 30" high and 65" wide would be adequate clearance (please measure your own car before you build as tire size,lowered ft end,aftermarket wheels with weird offsets may change things)

Having made the measurements, I bought the supplies and started cutting.
The width of the dolly is 6ft, so cut the 12ft 4x4 in half right in the middle to make the crossbars.
The sidebars are 4ft, so cut one 8ft 4x4 in half right in the middle
The legs are 24" long (+ the 6" casters = 30"), so measure the other 8ft 4x4 into 4 24" sections
You should have this
Image may have been reduced in size. Click image to view fullscreen.


I started with the long crossbars (6ft) and mounted the legs (2ft) to the ends of them using 1 angle and 3 plates per leg. The angle goes underneath the crossbar with mounts on top of the leg.
place the crossbar on the ground and attach the leg like this using some of the 200 smaller,shorter screws.
Image may have been reduced in size. Click image to view fullscreen.


Once you have the two crossbars attached to the four legs, turn them back over and attach the sidebars (4ft) inbetween them using 2 angles and 2 plates. angles are top and bottom, plates are on the sides
I attached the sidebars partway up the leg to allow room to actuate the brakes on each caster and allow space for the angles to be mounted underneath.
I spaced them up using another 4x4, but your distance can vary.
To make it a little easier,Attach the plates to the sidebars using the same smaller,shorter screws as before first like this
Image may have been reduced in size. Click image to view fullscreen.

then screw the plates to the legs and attach the angles on the top and bottom after the sidebars are attached to the legs(I forgot a pic here)

Once you have all the lumber screwed together, go back around and use as many smaller , shorter screws as you see fit. (I burned through all 200 of mine.)
then flip the entire thing over to attach the casters to the bottom of the legs using the larger, longer screws
Image may have been reduced in size. Click image to view fullscreen.

Depending on your caster purchase, they may not fit completely on the 4x4.
I forgot that a 4x4 is actually 4in by 4in, so mine hang over a bit. No issue.

Engage your locks, and then flip it back over and you are read to go
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


The Bug body on the dolly clears my 7ft (84in) high garage by under two inches, so I can roll it in and out. (measure yours first lol)
Image may have been reduced in size. Click image to view fullscreen.


all told, I'm out $135US because all the supplies were new.
Obviously, money can be saved using scrap wood,used casters,and screws that you already have on hand.
Sorry for lack of detail pics, I got caught up in the build and wanted to pull the body off as soon as possible.

lmk your thoughts and/or questions
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Contevita
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PostPosted: Sat Feb 09, 2019 3:54 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

Thanks for the info. I'll be building one soon but before I do that I'll need to build a cart/carrier to keep my doors and glass off the floor. Got any plans for one of those?
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slave1pilot
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PostPosted: Sun Feb 10, 2019 5:25 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

I do not.
That would have been a good idea, as all my parts are on the floor of 1/2 my garage
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My Photobucket for my Herbie Project - http://s1288.photobucket.com/user/TK-439/library/Herbie?sort=3&page=1

Currently:
1963 Ragtop Beetle
Previously:
1967 Beetle
1968 Beetle
1970 Beetle
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Busstom
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PostPosted: Mon Feb 11, 2019 12:36 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

Hehe, that was the first thing I thought of when I saw the header over your garage door...the finished rolling height!

slave1pilot wrote:
all told, I'm out $135US because all the supplies were new.
Obviously, money can be saved using scrap wood,used casters,and screws that you already have on hand.
Sorry for lack of detail pics, I got caught up in the build and wanted to pull the body off as soon as possible.

lmk your thoughts and/or questions

Looks great, cool for posting your BOM for others to get started. And look at it this way, when you finish your car next week Very Happy, you can repurpose those 4-bys on another project, or make blocks, or...
The only thing I'd add is some braces, maybe 12" overall length, at 45* angles on the insides of the long ends, just to mitigate any risk of racking. Say you're rolling along with some momentum, pushing on the Beetle, and one or both casters hit a gap, bump, tool, whatever may be on the floor, and the uprights may have a tendency to fold. Of course, the braces will hamper your crawl-through access from the sides, if only a little bit.
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slave1pilot
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PostPosted: Mon Feb 11, 2019 1:53 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

I did consider some 2x4's at a 45 angle
but honestly, I forgot to pick one up when I was shopping
_________________
My Photobucket for my Herbie Project - http://s1288.photobucket.com/user/TK-439/library/Herbie?sort=3&page=1

Currently:
1963 Ragtop Beetle
Previously:
1967 Beetle
1968 Beetle
1970 Beetle
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Chinaclipper
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PostPosted: Mon Oct 21, 2019 3:09 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

This looks very do-able. However, I need to replace my heater channels as well as my floor, and I wonder if I could extend the length so I could support from the aprons/ bumper area?
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cab57
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PostPosted: Mon Oct 21, 2019 10:05 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

Hi,

No problem to extend, I used this thread to built my body dolly but I have increased the size to work on heater channel.

Chris

Image may have been reduced in size. Click image to view fullscreen.

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Beetle convertible built 06/66
Beetle ragtop built 28/04/59


Last edited by cab57 on Tue Oct 22, 2019 1:14 pm; edited 1 time in total
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Chinaclipper
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PostPosted: Tue Oct 22, 2019 9:01 am    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

I LIKE it! Could you give me the measurements? I have a '71 Super but I THINK it would work they way you show it....
Also, is it wide enough to store your chassis with wheels on underneath it? I am in a place where space is at a premium...
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Dibaltic
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PostPosted: Tue Oct 22, 2019 9:17 am    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

Chinaclipper wrote:
I LIKE it! Could you give me the measurements? I have a '71 Super but I THINK it would work they way you show it....
Also, is it wide enough to store your chassis with wheels on underneath it? I am in a place where space is at a premium...


I used two 8 foot long 4x4 posts for the length and two 6 foot 4x4 posts for the width. It stores the chassis perfectly underneath and lets me roll the car in and out of the garage as needed.

Image may have been reduced in size. Click image to view fullscreen.
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cab57
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PostPosted: Tue Oct 22, 2019 1:09 pm    Post subject: Re: Type I Bug Body Dolly (cart) build plans Reply with quote

Yes like the previous picture of dibaltic, my chassis goes under the body.
I have space restriction too and I made the shorter height that I could.

But I had an small issue with my wheels and heater channel when I tried to move the body. So I added some pieces of wood (that you can see on my picture) just to move the body.

The best for you is to take your measures, this is not very hard and it will fit perfectly your beetle.

Chris
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Beetle ragtop built 28/04/59
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