BUILD YOUR OWN TOW DOLLY

COMPLETE STEP-BY-STEP PLANS AND

MATERIAL I CUTTING LIST

GROSS TRAILER CAPACITY 3,500 LBS EMPTY WEIGHT 1050 LBS EMPTY TONGUE \VEIGlIT 90 LBS

16 Linear feet 11 "

6 "

25 "

8 Square feel 7 "

10 "

25 "

5

17 Linear Feet 1 "

3 "

9 "

} "

Tow dolly materials list STEEL STOCK

1;';" X 3" x 3" sq Tubing 3/16" x 2" x 2" sq Tubing Yo" x 3" x 3" Angle

Yo" x 2" x 2" Angle

W' Diamond Plate

1/8" Flat Plate

3/16" Flat PI.8te

W' Flat Plate

3/8" Flat Plate

3" Channel (5 los/foot grade) 1 7 fJ 6" Round Bar (HRR)

y," Round Bar (HRR)

I W' Schedule 40 Black Pipe 1 W' Double heavy Wall Pipe

NOTE:

The amounts above are for the EXACT needs and do not inclnde material for the kerf (waste) from culting, please adjust accordingly (saw cutting makes 1= waste tben torth clltting for example)

OTHER SUPPLIES

SAE GRADE 8 BOLTS WITH LOCK WASHERS, FLAT WASHERS & NUTS 3/8"x}".4ea

3/8 x 1 Yo 8ea

Y." xl" 4 ea

Y." x 3 y," 4ea

W' x4 v." 7ea

\1," x 6" 2e.a

Y." x 4 y," high by 1 y," wide U-Bolt wi washers and nuts lea 2" BaU 7,000 Lb min coupler lea

Bolt on spindle (suggested GM Part # 7470503 .. check wrecking yards) 14" Rims & Tires

9" x 19" x 32" fenders (check northerntool .com) 3/8" x 150" safety chain with 2 hooks

Trailer Lighting Kit

Spring Latches with Yo shanks & Lock

DISCLAIMER

As we have no control over the builder's abilities or material choices, we DO NOT WARRANT these plans for any type of suitability of use and offer them fOT experimental use only.

STEP ONE

SPINDLE SELEC.TION

SVPPLYLIST

(2) SPINDLE HUBS WrTHSTUOS AND WG NUTS, 1750 La MlNlMUM CAPACITf EACH DESIGNED TO ACCOMODAiE 14' WHEfELS.

(8) 318'X1 1/Z' SAE GRADES BOL T.S WffH LDCK WASHERS IWD NUTS.

THE HUB AND BEARING SUGGESTED IS FROM REAR AXLE OF 7}fE LARGER GeNERAJ... MOTORS FRom WHEEL ORNE VEHICLES. PART NUMBER 7470S03

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STEP TWO

SPINDLE MOUNTING COMPONENTS

1/4' RAT STEEL PLATE

CUTUST

(4 NEEDED)

(2 NEEDED)

(4) PIECES OF:r X:r X 31B" FlAT PLATE

(2) PIECES OF 4 1/2:'X 4 1/2:' X 3/8' FLAT PLATE HOLES PLACED AS SHOWN

(2) PIECES OF 3 3/4' X 1f1' X 31B" FLAT PLATE HOLES PLACED AS SHOWN

(4) PIECES OF71/8" X lf1' X 318" FLAT PLATE (2) PIECES OF 4 1 ;2' X S' X 1/4" F!.AT PLATE

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1-3"-1

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1-4112'--/

(4NE£DED)

(2 NEEDED)

(2 NEEDED)

CHAMFER AND DEBUR (HOLE TO BE USED FOR WIRING ACCESS TO FENDER

UGHTS.) .

L__j_41! ~/2"

11/2'

CUT & DRILL HOLE PATTERN TO FIT SPINDLE. CENTER ON PLATE.

~~

STEP THREE

AXLE & SPINDLE ASSEMBLY

CUT lit SUPPLY LlST

(1) PIECE OF 3' X 3" X 1/~ SQUARE 1UBfNG 7ft' LONG, CUT SQUARE ON BOTH ENDS.

·COMPONENTS FOR SPINDLE MOUNT FROM STEP ONE.

SQUARE BOrn fENDS OF 3' TUBING

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WELD 3"X:f'X311!' PIAn:. ON EACH SIDE AS SHOWN.

WELD 3 a/4"X1C1'X3/£I' PLATE SQUARE ON END AS SHOWN..

·STEP THREE

AXLE & SPINDLE ASSEMBLY

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. AXLE & SPINDLE.ASSEMBLY.

,STEP FOUR

!ONGUE AND COUPLER CUT & SUPPLY UST

IZ) Pla;E$ :l?(3"X1/4' SQUARE roSING, 46 5/ft' LONG CUT SQUARE ON ONE END AND .w ON THE OHTER..

If) PIECE 3"'X3"X1I~ SQUARE TUSING.

11 fir LONG cur.4$' ON BOTH END$; (2) .PIECES3"X1 14" FIAT PLATE,

12 l/T LONG, SQUARE ON BOTH ENDS.

If} PIECE 3"X1 14" FLAT PLATE. 16" LONG, CUT AT 4S" ANGLE ON BOTH ENDS AND DRILL T "T HOLE AS sHOWN.

(1) PIECE 3"Xl/4" FLAT PLATE, 16" LONG, cur SQUARE ONSOTH ENDS AND BENTTOFlT.

(1) 7,000 UJ CAPACI1T TSALL COUPLER 3" SQUARE TUBING ATTACHMENT.

If} .PUll WIRE 10' MINIMUM. FOR PUWNG flECTRlCAL WIRE.

:rX3'X1/4' SQUARE TUBING

(1 NEEDED) '< oW T'fP.

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THEJiE ARE SMRAL STYI.ES OF COUPLERS AVAlLMLE: THE ONE DEPICTED BELOW WAS CHOSEN FOR fT'S PROVEN RELlABIUTY.

(1 NEEDED)

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(2 NEEDED)

1/4'PLA7E

,STEP FOUR

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-STEPFOUR

TONGUE AND COUPLER

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SUPPLY t- cur LIST

TONGUE MOUNTING HARDWARE

, (4) PIECES 3'X3'X1/4" ANGLE,

1(;' LONG, cor SOUAAe, DRILL '. 1/2" DIA. HolEs AS SHOWN.

(4) 112'X4 1/2" &liE GRADE 680£.18, LOCI( - WASHERs AND NUTS. ,

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(4 PIECES NEEDED)

}Rlll 1/2" DIA I 1(1' ~

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STEP SIX

RAMP POCKETS

CUT LIST

(4) PIECES 3' STANOAiID CHANNEL

(5 LBS. PER FOOT), 34" LONG, CUT SQUARE ON BOTH ENDS. }WO OF THE PIECES ARE TO HAVE HOLES ORILLED AS SHOWN.

THE$E7WO 8" CHANNEL SECTIONS WiTH THE EARS ANO 5/S' DIA. HOLES ARE TO BE PLACED ON THE OlfTS/DE OF THE TRAILER IN ORDER TO MAKE FOR EASY ACCESS TO

THE RAMP LATCHES.

NOTE: RAMP SPRING LATCHes WILL BE WELDED ON IN STEP NINE.

(2 PIECES NEEDED)

1-------34' fJ5/B' 1_r1112'

1112Jb

(2 PIECES NEEDED)

I-------------~.------------~

._____----________jJ

STEP SIX

RAMP POCKETS

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~ STEP SEVEN

RAMP POCKETS CON'T.

CUT LIST

(4) PIECES'4"X151/2'X1/4' FLAT PLATE CUT SQUARE ON BOTH ENDS, DRILL lIZ' HOLES IN 7WO PIECESAS SHOWN,

(2) PIECES 2"X2"X1/4' JINGLE,

8' LONG, CUT SQUARE, DRill 11Z'D/A HOLES ~ SHOWN.

(2) PIECES 15 1/2"X34'X1/4" FLAT PLA TE cur SQUARE ON BOTH ENDS.

(2) PIECES 1f?'X33 1/2")(1/8" FLAi PLAi"E cur SQUARE ON BOTH ENDS.

(2) PIEcEs a"X151/2"X3/18' FLAT PLATE cut SQUARE ON BOTH ENDS.

(4) 1/2'X1° SAE GRADE_8 BOLTS, LOCK WASHERS AND NUTS,

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THIS 1/8' THICK PLATE IS TO BE WELDED INTERMITTENTLY SO THAT IT CAN BE REPLACED IF EXCESSNE WEAR OCCURS.

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15"X33 1/2!'X1/8" FI.ATPLATE

1/4'X4"X151 PLATE(TYP

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1/4' TYP.

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STEP SEVEN

RAMP POCKETS CON'T.

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STEP NINE

RAMP SPRING LATCH

. SUPPLY LIST

,(2) SPRING LATCHS, WITH 1/2' SHANK AND LOCK.

THE FRONT ANGLE OF THE RAMP FRAME IS TO FIT OVER THE 2"X2" ANGLE ON THG RAMP POC!<ET..THE ANGLE ON THE RAMP POCKEl' MAY HAVE TO BE UNBOLTED TO ALLOW THE RAMP 70 SUDEIN70 POSITION. THE LATcH IS TO MATE WITH THE HOLE IN THE RAMP WHEN IN THE TRANSPORT POSITION.-

THE LATCH Will NEElJA SLOT TO LOCK IT IN THE OPEN rosmON TO FREE /HE OPERATORS HANDS WHEN SLIDING THE RAMPS INTO THE RAMP POCKETS.

STEP TEN

FENDERS, LIGHTS AND LICENSE PLA TE BRACKET

'TE: THE FENDERS, MOUNTING PLA TES AND LIGHT BRACKETS ARE ALL 'EN AS APPROXIMATE DESIGN AND DIMENSIONS. THE FENDER SHAPE

o DIMENSIONS VERY ACCORDfNG TO THE MANUFACTURER. SEVERAL TAILS ARE SUGGES1ED: USE 3/1_6" FLAT PLATE MATERIAL FOR FENDER CKS, THE 18 GAGE MATERJAL THAT NORMALLY COMES WITH FENDERS ~OT STRONG ENOUGH CONSIDERING THAT THESE ARE ACTUALLY THE JVNTING BRACKET AS WELL. FENDER MOUNTED LIGHTS ARE PROVIDED SOME MANUFACTURERS, HOWIfVER IF THESE ARE NOT USED THE IUNTING BRACKET SHOWN IS A DURABLE ALTERNITNE

(J318"

SUPPLY AND CUT LIST

(2) 9' WIDE, 16 GAGE, FENDERS TO ..

ACCOMODATE 14" WHEELS AND TIRES.

(2) Pl/~CES 3/15' TrifCK FLAT PLATE APPROX. 32'X16" cur TO FIT FENDERS.

(2) PieCES S'X17"(APPROX)X3116' FLAT

PLA TE. BEND so AS TO ONE 7" BY 10" DIMENSIONS AS SHOWN BELOW. WITH HOLES DRILLED TO MOUNT LIGHTS AND UCENSE PLATE.

(2) SI16'Xl"X1rJ' TRIANGL.ES, CurTO FIT. (4) 3!B"X1' SAEGRADE 5 BOLTS, LOCK WASHEFiS AND NUTS.

STEP 'ELEVEN

CUTL/ST

(1) PIECE 72"X30''X1/4'' FLAT PLATE.

CUT AS SHOWN.

PAN PLATE

1---16'--~+---------40"---------"f----1B"----t

30'

STEP TWELVE

PAN FRAME '

, CUTLIST

(4) PIECES :J' STANDARD CHANNEL, (5.0 LBS. PER FOO1)

16" LONG, CUT SQUARE AND DRILL HOLES AS SHOWN. (4) PIECES 2")(31")(1/1f' FLAT PLiUE

(2) PIECES 5"X16"X1/4" FLAT PLATE

(4) P/~'CES 3'X4"X1/4' FLAT PLATE, NOTCHED AND DRJLLED AS SHOWN. (2) PIECES 6 7/fJ"X1(J'X1/4' FLAT PLATE, CUT AS SHOWN.

, (2) PIECES 3 13116")(15 1/2'X1!4' FLAT PLATE, CUT AS SHOWN •.

, (2) PIECES 5 112""X71/2'X1/4' FLAT PLATE, CUT AT ANGLE AS SHOWN. (2) PIECES 5 1/Z'"X6112"X1/4' FLAT PLATE, CUT AT ANGLE AS SHOWN. (4) PIECES 1·X2."X8/ff' FLAT PLATE

(2) 1/2" DIA, 161/2' LONG COLD ROLL ROUND BAR

(1) PIECE 2X2"X3/16" SQUARE STRUCTURAL TUBING(4.3LBS I FOO1), 71 1{2' LONG, NOTCHED ON Born ENDS TO FIT OVER 2'X2;'X1I4' ANGLE AS SHOWN:

(1) PIECE 2X2'X3/16" SQUARE STRUCTURAL TUBING(4.3LBS I FOO1),

40' LONG. CUT SQUARE ON BOTH ENDS. .

(2) PIECES 2X2"X3/16" SQUARE STRUCTURAL TUBING(4.3LBS 1 FOO1), 8" LONG. CUT SQUARE ON BOTH ENDS.

(4) PIECES 2X2''X114' ANGLE, 81/2" LONG CUT SQUARE ON ONE END AND AT 45" ON THE OTHER AND TWO 1 {2' HOLES DRILLED IN EACH AS SHOWN.

(4) PIECES ?X2"X1/4' ANGLE, 17 112" LONG CUT SQUARE. BOTH ENDS.

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63/16'. r'1/2"
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13"
171/2"
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71/2

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STEP TWELVE

PAN FRAME

(2NEEDEO)

i-231f4f1------1"'!

45'! ---:12' 7/8" _

79o_

1-1. ---28"'----?>l~

'--i2·rrl~~ .»: 45~~

. (.:_B 1/2"_j

'(4 NEEDED)

3/8"

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STEP

T HI RT E E N g~~;1~~2' DOUBLE EXlRAHEAWWALL PIPE

1'LONG.

PNOTASSEMBLY .

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~_____ 51/4'

I . I~. ~~I' _l SQUARE CUT FOUR SLOCKS OF WOOD 5 1/4" LONG AND PLACE BE1WE£N BASE PLATE AND FLANGE PLATE TOASSURE THEIR BEING PARAUEL WHEN WELDED.

1" .. SJ_l

CJ [ DRILL HOLE FOR . 2 1/4' D ~8.

T GREASE ZERT. I _i

1/4 fU4 D::6Btt/o~H:;AY

J 6112

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1/8 CHAMFER ,

f WITH ALL THREE COMPONENTS ASSEMBLED. AND AN 1/B" SPACE BETWEEN THE TWO RINGS, DRILL rwo 1/Z' DlAMf!TER HO~S AS SHOWN ALL THE WAY THROUGH THE PIPE AND THE PIN. AFTER DRILUNG ONE, PLACE 1/2' BOLT IN IT TO ENSURE AUGNMENT WHILE DR/LUNG THE OTHER HOLE.

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---l 4 7/B" I-

1')-

31B" FLAT PLATE

18"1

r \__f)1/2~ P. 8 L ..

4"

4,-l---

GREASE ZERT TO BE TURNED TOWARD REAR FOR TRAILER.

1'TYP.

(1) PIECE 11/2" DOUBLE EXTRA HEAVY WALL PIPE 21/4" '_ONG. DRILL (AND TAP IF NEEDED) HOLE GREASE ZERT A.S SHOWN.

(1) piECE 1112' DOUBLE EXTRA HEAVY WALL PIPE 4 318" LONG.

(1] PIECE 1 7116" COLD ROLL ROUND BAR, 7'3/4' LONG, CHAMFER ON ONE END.

. (2)1/2'X31/2' SAE GRADE 8 BOLTS WITH FLAT AND LOCK WASHERS.

(2) PIECES 8'X121/2''X3/8' FLAT PLATE, DRILL EACH AS SHOWN.

(4) PIECES 3"X4 7/8"X318" FLAT PLATE, CUT TRIANGLES AS SHOWN.

(1) GREASE ZERT, THREADED OR DRNE IN.

90"~ { ___Lj

TACK WELD PIPE TO PLATE AS SHOWN, DO NOT PLACE TACKS WHERE TRIANGLES ARE TO GO. CHECK fOR SOL/ARE, THEN TACK ALL FOUR TRIANGLES INTO POSmON, CHEc;K FOR SQUAAE THEN WElD COMPLETE; BEING CAREFUL· TO ALTERNATE WELDING SEQUENCE TO MINIMIZE HEAT DlSTORTION.

PLACE TWO 1/2' BOLTS IN HOLES WHILE WELDING, DISCARD AFTER US!;.

I

STEP FIFTEEN

CLEAN /PREP/ PAINT

BEFORE PAINTING THE ENTIRE TRAILER SHOULD BE CLEANED AND FREE FROM RUST OR GREASE. TO ACCOMPUSH THIS ALL SURFACE AREAS SHOULD BE WIRE BRUSHED AND/OR SANDED. IF SEVERE RUST IS' PRESENT SANbBLASTING SHOULD BE CONSIDERED. THE WELDED AREAS SHOULD BE CHIPPED OF ALL SLAG OR RESIDUE AND WJPED CLEAN WITH PAINT SOL VENT. ONE OR TWO COATS OF PRIMER PAlNT SHOULD BE APPUED, AND ONE OR TWO COATS OF TOP GRADE ENNAELAS THE FINAL APPUCATION. PAINT ACCORDING ro MANUFACTUR/?RS RECOMMENDATIONS AND SAFE7Y GUIDELINES.

STEP SIXTEEN

··WIRING

FOLLOW WIRING DfAGRAM PROVIDED OR FOllOW INSTRUCTIONS THAT COME WITH YOUR LIGHTING nt:

CHECK wrm. YOUR STATE: AGENCY ABOUT LlGHTlNG AND SAFElY REQUIREMENTS SUGGESTED ROunNG OF WIRE IS THROUGH TH.~ SO SfJUARE TUBING, EXTERNAL ROUTING MAY BE PREFERRED. SECURE WELL AND

. PROTECT. THE ROUTING THROUGH OR AROUND fENDERS MUST BE DONE IN CONDUIT IF EXPoSED TO TIRES.

STEP SEVENTEEN

'W:EB RATCHET S_LfOE B~CKET

SUPPLY AND CUT LIST

(2) PIECES 4 1/2'')(4'')(3/8" FLAT PLATE

(2) PIECES 2"X4''X3/Iff'-FLAT PLATE

(2) WEB RATCHETS WrtH TIE DOWN WEBBING

BUCKLES & HOOKS. '

(4) 1j2"X1" NC SAE GRADE 8 BOLTS

WEBBING NOT SHOWN

¥!J'14'

B1/2'DRlLL AND TAP

1/2" NO TO FIT WEB RATCHf!T

USE EX/SnNG HOLES IN WEB RATCHET JF POSSIBLE, IF NOT DRILL NEW ONES. USE SAE . GRADE 8, 1/2"NCX1'LONG.

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STEP NINETEEN

SAFETY CHAINS

. SUPPLY LIST

.(2) PIECES 4 1!2"X-rX3/8" FLAT PLATE (2) PIECES 2"X4'X;J/ff' FLAT PLATE 150+' 31S" PROOF CHAIN AND 7WO CHAIN HOOKS, CUT CHAIN TO FrT AS SHOWN.

(1) 1/2'X5" NC, SAE GRADE 8 BoL T, WITH TWO WASHERS AND NUT. (2) 1/2")(6" NC. SAE GRADE 8 SOL T$, WITH WASHERS AND NUTS.

(1) 1/2' SAE GRADE S, U-80L T WITH WASHERS AND !JUTS, LONG ENOUGH TO SECURE CHAIN TO TONGUE.

CUT CHNN TO FIT SO THAT THE PAN OR THE TOED VEHICLE CANNOT SWNEL AND INTERFERE WITH THE FENDERS, TfRES OR SPINDLE BRACKETS.

I

LIGHTING / WIRING SCHEMATIC I

THIS ISA CoMMON .

ELECTRICAl.. SCHEMAT1C FOR CAR DOWES, HoWEVER SOME srATES MAY REQUIRE ADDITIONAL FEATURES. THE AMBER CLEARANCE MAY NOT BE REQU1RED, HOWEVER THer PROVIDE SAFETY AND AllOW THE DRNER TO HAVE ASSURANCE THAT THE UGHTSARE FUNCTIONAL

AMBER CLEARANCE

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WIREs RUNNING UNDER tHE TRAILER SHOULD BE ENCASED IN A CONDUIT OR WITHIN THE FRAME

AS THE PlANS SHOW

FOR PROTECTION.

Ci£ARANcE AMBER

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