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See https://jarkman.co.uk/catalog/luggage/collapsingtrolleyv2.htm for more
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How many?Length (mm)
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Side rails50.8mm x 38.1mm x 3.2mm21160You could make this a bit longer if you want eurocrates to pack tidily - aim for 1200mm of payload space
aluminium-online.co.uk
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Aluminium Channel
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(2" x 1.1/2" x 1/8"
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Handle rail adapters50.8mm x 38.1mm x 3.2mm2100
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Cross rails38.1mm x 25.4mm x 3.2mm4410You could make these a bit longer too, aim for 800mm between the side posts to have Eurocrates fit tidily. You'll want to do some shaping on the ends of these (see photos) to let them articulate properly.
aluminium-online.co.uk
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Aluminium Channel
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(1.1/2" x 1" x 1/8")
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Handle rails38.1mm x 25.4mm x 3.2mm21100You could alternatively use the side rail section for this, which saves making the adapters. The angle cut on the end of the handle rails and side rails should be chosen to bring the handle to a comfortable height for you.
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Cross rail end pivotsM6 stainless bolt460
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Cross rail center pivotsM6 stainless bolt250
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Stainless M6 washers and nylocs
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Cross rail end spacers12.6x6mm tube431
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12.6x6mm tube46
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Cross rail center spacers12.6x6mm tube228
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Side posts12.6x6mm tube6270
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Stop bolts for side postsM3x16 bolts, nylocs6
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Hinges80mm stainless2
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Countersunk bolts & nylocs to suit hingesI used m5x158
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Bolts for handle rail adaptersM64
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Wheels260mm pneumatic wheels2These are fine, slightly bigger wheels would give you a bit more ground clearance, say 350 or 400mm
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AxleSteel rod or tube (ideally stainless) to suit wheel bearings1
length determined by wheel thickness
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Wheel spacersIf your wheels need a spacer to stop them rubbing on the side railI have a slightly ridiculous arrangement made from bits of old photocopier. You can do better.
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R pins for axle2
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Handle tube20mm Al tube or rod1400
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31.5x26x3.2mm Al channel2100Welded up from sawn-down scraps of channel to be a good fit into the handle rails. If you use the bigger section for the handle rails you need different dimensions here. There should be a better way to make the handle assembly without welding, but I did not think of it. Please have a go and let me know.
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R pins for handle2
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PVC mesh fabric for bed1
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Webbing sewn to mesh to reinforce for lacing
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Paracord to lace bed to side rails
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6mm bungee for the captive elastics that hold it rolled up
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6mm bungee for top edges4000
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Bungee hook ends8https://www.ropesandtwines.com/proddetail.php?prod=self_assembly_6mm%2F8mm_plastic_bungee_cord_hooks
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