DIY Heavy Duty Trolley Step by Step/Van mount, pics (PART 1)

Discussion in 'Tutorials & DIY' started by jimmyboots, Mar 21, 2015.

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  1. jimmyboots

    jimmyboots Forum Addict
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    Here is a step by step how to make a Heavy Duty Trolley with Shurflo pump, filter, Spring controller and reel.
    Apologies for lengthy thread in advance :)

    First here are the main components to the Trolley. Small things like switches , nuts and bolts shall be mentioned as I go along.
    Trolley, Pump, filter with connections, spring analogue controller, electrical boxes, 22ah battery and 10mm ID reinforced clear hose.
    [​IMG]

    first Idrilled holes at the desired height for the trolley so the adjustable connections lock the handle
    [​IMG]

    Then I cut 2 pieces of 30mm angle steel and 2 pieces of galvanised electrical conduit to the width of the Trolley
    [​IMG]
    [​IMG]

    Next I attached the metal to the Electrical boxes with small nuts and bolts.
    [​IMG]

    Then I drilled holes into the Trolley and attached the boxes to it. (Don't permanently screw to the trolley yet)
    [​IMG]

    Next I removed the large bottom box from the Trolley, positioned the pump and strainer and screwed the pump to the box through the rubber feet with nuts and bolts. (dont over tighten)
    [​IMG]
     
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  2. jimmyboots

    jimmyboots Forum Addict
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    [​IMG]

    Next I drilled entry and exit holes for the Hose
    [​IMG]

    Then, I unscrewed the Spring controller and attached the back casing to the top of the pump box

    [​IMG]


    Then reasemble the controller and attach the blue and brown wires to the black and red wires of the pump
    [​IMG]

    Attach the 2 boxes back to the Trolley with 40mm nuts and bolts.
    Using a piece of clear hose to protect, drill a hole through the 2 boxes and guide the remaining black and red wires through the clear hose up into the Battery box.
    [​IMG]
    [​IMG]
     
  3. jimmyboots

    jimmyboots Forum Addict
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    Next I fitted the on/ off switch and the charging plug. The on/off is optional as it can be turned on/off at the left dial on the flow control, but, I like to keep the dial set in the same position so a separate on/off switch allows that.
    [​IMG]
    [​IMG]

    On the other side of the battery box I put a voltometer to keep tabs on the battery with its own on/off switch.
    [​IMG]

    Then put all the wiring and fuse in ready for the battery.
    [​IMG]

    [​IMG]

    Next, I did the reel. This is the SMALL reel from Wilkos. Assemble reel.
    [​IMG]
     
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  4. jimmyboots

    jimmyboots Forum Addict
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    The reel is attached to the Trolley by drilling through the ends and the Trolley while the top is held with a jubilee clip as pictures
    [​IMG]
    [​IMG]
    [​IMG]
     
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  5. john39

    john39 Well-Known Member
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    you do I great job jimmy
     
  6. cornishcraig

    cornishcraig Newcomer
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    Hi Jimmy
    great trolley set up what great inspiration that gave me.
    where did you get the digital volt meter from??

    Thanks
     
  7. jimmyboots

    jimmyboots Forum Addict
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  8. Gary63

    Gary63 Member
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    Brilliant trolley build and great clear pics.
     
  9. jsmc

    jsmc Member
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    where would be best place to get that conduit?
     
  10. mark m

    mark m Hero
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    the best diy trolley by a mile
     
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