Large Garden Cart
Qty Description Qty Description
(10) 1-3/8" bolts (2) leg stands
(22) 5/8" bolts (1) leg brace
(8) 3/4" bolts (1) 42-1/2" x 3/4" steel axle
(6) 1/4" x 20 lock nuts (2) 26" wheels
(6) 3/4" full clamps (1) bottom panel
(2) 3/4" half clamps (2) side panels
(2) 1/2" axle clamps (1) front panel
(2) front panel brackets (2) cotter pins
(1) U-Brace (2) extra 5/8" bolts
(2) aluminum angles (2) extra T-nuts
Tools you will need:
* nail or awl
* adjustable wrench
* Phillips screwdriver
Helpful hint: During assembly, you may find it helpful to use a nail or awl to line up the holes when placing bolts. If you have difficulty assembling your cart, please contact us: (email@example.com or 1-888-833-1412).
Step 1. Lay out the bottom and side panels on a clean flat surface. Arrange the hardware so it's easily accessible. We've included extra 5/8" bolts and T-nuts in case one is stripped during assembly. Note: The cart panels come with the T-nuts already installed. The 5/8" bolts screw into the T-nuts.
Step 2. Please refer to Fig. 1 for this step. Place the side panels inside the support angles of the bottom panel. The wide side of the aluminum trim on both panels should face out. Using the 5/8" bolts, attach each side panel to the bottom panel by placing a bolt through holes A and C from the outside. Tighten the bolts on each side.
Step 3. Working on the reverse end of the cart (opposite the lip), position the welded U-brace as shown in Fig. 2. Do not use bolts to attach the U-brace until Step 4.
Step 4. While holding the U-brace in place, put an aluminum angle into each corner of the U-brace with the cut of each angle sloping inward (Fig. 3). From the outside, align the top and bottom holes in the U-brace with the holes of the side panels and aluminum angles. Insert two 1-3/8" bolts into each side and firmly tighten on the inside with a lock nut (Fig. 3). The U-brace and aluminum angles provide a channel for the front panel to slide up and down.
Step 5. Find the front panel and attach the stop brackets to the side of the panel with the wider trim. Insert three 3/4" bolts into each bracket and fasten tightly (Fig. 4).
Step 6. Place the front panel in the channel with stop brackets facing out to make sure the panel opens and closes freely (Fig. 5). Adjust the aluminum angles if necessary. Remove the front panel.
Step 7. Turn the cart body upside down to attach the handle to the bottom of the cart as shown in Fig. 6. Place two 3/4" full clamps over each side of the handle to line up with the pre-drilled holes in the bottom panel. Use 5/8" bolts to loosely attach the clamps to the bottom panel. Adjust the handle to the desired distance from the body of the cart, then firmly tighten the bolts.
Step 8. Attach the legs to the side panels. Insert 1-3/8" bolts through the leg and into holes B and D on each side panel (Fig. 7). Do not fully tighten the bolts.
Step 9. Using the 1-3/8" bolts and lock nuts, attach the leg brace to each leg as shown in Fig. 7 and loosely tighten each nut with a wrench. Next, secure the leg brace to the bottom panel using two clamps and 5/8" bolts as shown.
Step 10. Use the two half clamps to attach the end of each leg to the bottom panel. Line up the hole in the leg with the hole in the bottom panel. Place the rounded part of the clamp over the handle (see the enlarged view, Fig. 7). Insert a 3/4" bolt through the half clamp, the leg, and into the bottom panel. Firmly tighten the bolt on each half clamp. Fully tighten all bolts and nuts on the legs, leg brace, and handle.
Installing the Wheels
Step 11. Put one end of the axle through a wheel hub (Fig. 8). Insert a cotter pin through the small hole in the axle that is located on the outside of the wheel hub. Spread the ends of the cotter pin apart to form a "Y" around the end of the axle.
Hold the other end of the axle and slide on the remaining wheel. Insert a cotter pin into the small hole in the axle and spread the ends of the pin apart to form a "Y".
Position the axle on the bottom panel so that the wheels line up evenly on both sides. Fasten the axle to the bottom panel using the narrow axle clamps and two 5/8" bolts per clamp (Fig. 8).
Garden Cart Maintenance
Protect your cart from harsh weather and extend the life of the plywood by storing it in a shed, garage, or under a tarp. Be sure to clean out debris with a broom and allow the cart to stand in sunlight to dry.
To extend the life of the plywood, repaint or stain it every two years. We recommend a natural stain that will not contaminate compost, soil or other garden materials you may carry in the cart.
Keep the tires inflated to the rated pressure indicated on the tires to prevent damage to the tread or tube. If you need to replace a tube, use a 26" tire tube, or repair a flat using a tire repair kit.
Use caution on slopes. These carts do not have brakes and make roll away from you.
Do not exceed the load recommendation of 500 lbs. for this cart.
Distribute weight evenly when loading the cart. An uneven distribution of weight could cause the cart to flip up unexpectedly and cause injury.
If you have any questions, contact us at: firstname.lastname@example.org