The modular plug-in system allows for easy assembly without welding or special tools. In addition, you can adapt the panel trolley individually to your needs.
Build your own panel cart - Building instructions with ALUSTECK®
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discount - Professional
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lightweight aluminium - Cutting
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With ALUSTECK® you can easily build a stable aluminum panel cart for your production in custom dimensions for transporting panel material. The aluminum plug-in system offers diverse possibilities for the construction of various operational facilities, for example for sign-making companies. This building instruction shows you step by step how a panel cart for transporting bulky items is built with ALUSTECK®.
Products for building a panel cart
Easily configure materials for your kit online!
Adjustable foot Swivel castor with brake / Ø 50mm Appliance castor Castor with brake Ø50mm
€4.95*
€4.95*
Connector 25×25 Swivel Joint Connector, 45 to 195 Degrees Adjustable, 25x25mm Push-fit Connector for Square Tube Swivel connector 45–195° €4.16*
Variants off €3.78*
From €3.78*
Connector 25×25 Right Angle 25x25mm Connector Square Tube Right angle €2.86*
Variants off €2.57*
From €2.57*
Online cutting service:
Profiles cut to size! 955mm
Profiles cut to size! 955mm
You can get materials such as aluminum tubes for the frame of the panel trolley, cut precisely to your specifications, directly in our online shop. In combination with the special plug-in elements for easily connecting the tubes, you will quickly receive a customized kit.
Professional Advantage: Build a customized panel trolley construction with ALUSTECK®.
Because we cut all tubes for the aluminum panel trolley frame precisely to your specifications. You receive the tubes from us pre-cut to size. A panel trolley with ALUSTECK® is an inexpensive, robust alternative and easy to implement.
Build your own panel trolley step by step:
With these building instructions, we show you step by step how to build your individual panel trolley without much effort. These building instructions for a transport trolley for panel material are just an example and can be individually adapted to your needs. Many other designs, such as tool trolleys or picking trolleys, can be realized with a little creativity. Before the final assembly of the panel trolley, the individual modules are first assembled and then connected to each other.
The assembly for building the panel trolley takes place in 3 steps
Module E1: trolley chassis
Module E2: panel support
Panel trolley assembly
In 1.) Step, the base, the trolley chassis module, is assembled. In 2.) Step, the plate support module is assembled. In 3.) Step, the complete assembly of the two modules into the finished plate trolley then takes place.
Step 1: Build the Trolley Chassis Module (E1)
You will need the following components from your order for the panel cart rolling chassis
Parts list – products from our online shop:
Item | Name | Variant | Item no. | Quantity |
1 | Aluminum profile 2 webs 15 mm external angle | Length: 860 mm, Cutting diagram: A | R-2ST-WA-SI | 2 |
2 | Aluminum profile without web | Length: 483 mm, Cutting diagram: A | R-V25-SI | 2 |
3 | Self-tapping screw | 4,8x19mm | AS02114819 | 12 |
4 | Right angle | grey | 2D2V25-X1.5MK-RAL7035 | 4 |
5 | Swivel castor with brake / Ø 50mm Appliance castor | AS-A220.A80.050 | 2 | |
6 | Swivel castor with brake / Ø 50mm Appliance castor | AS-A220.A80.050 | 2 |
For the construction of the frame or chassis of the floor element with industrial castors, the connectors are simply hammered into the tubes. In the upper illustration, you can see all the necessary materials and tools that are required in step 1 for the construction of the first module.
1. Mark and drill the drilling points
Determine 4 drilling points per tube with 2 webs in the outer angle (01). Drilling is done on only one web side. Set 2 drilling points on the right and left 50 mm from the edge and 2 more 250 mm from the edge!
2. Holes with a metal drill bit (4 mm)
Drill the marked hole positions with a cordless screwdriver and a 4 mm metal drill bit. Repeat this on the 2nd profile as well.
3. Assemble the trolley chassis
Make sure that the holes of the aluminium-profile webs (01) are on the outside and face upwards. Now connect the aluminium tubes (01 + 02) with the corner connectors (04) into a frame by driving them together.
4. Screw on the castors
In the last step, simply screw the industrial castors with rubber wheel (05) onto the aluminium frame from below at all 4 corners. The webs of the profiles must point downwards here. Our module (E1) is finished.
Step 2: Build the Plate Support Modules (E2) for the Trolley
You will need the following components from your order for the panel support construction
Parts list – products from our online shop:
Item | Name | Variant | Item no. | Quantity |
7 | Aluminum profile without web | Length: 250 mm, Cutting diagram: A | R-V25-SI | 4 |
8 | Aluminum profile without web | Length: 260 mm, Cutting diagram: A | R-V25-SI | 4 |
9 | Aluminum profile without web | Length: 300 mm, Cutting diagram: A | R-V25-SI | 4 |
10 | Joint connector 0 to 270 degrees swivelling | grey | VS2D2V25K-GELENK270GradR7035 | 8 |
11 | End cap, Threaded plug | thread M10 | VL25X25M10S-1 | 8 |
12 | Right angle | grey | 2D2V25-X1.5MK-RAL7035 | 8 |
13 | Aluminum profile without web | Length: 1200 mm, Cutting diagram: A | R-V25-SI | 8 |
14 | Self-tapping screw | 3,5x13 | AS02113513 | 8 |
For the construction of the plate support, all materials and tools shown in the upper figure that are needed for step 2 to build the second module are depicted.
A: Connecting the Assemblies
1.1 Material for assembly A1
For building assembly A, use the aluminium tubes (07) and the threaded tube plugs (11). In addition, please also glue the tubes to the plugs here.
1.2. Drive in the threaded plug
Apply adhesive to the tenons of the threaded plugs and drive them into the aluminium tubes with a plastic-headed hammer. The assembly (A1) that we need in the next step is now finished.
2.1. Material for assembly A2
For the further assembly of assembly A2, we now need the previously created assembly (A1) as well as the joint connectors (10) with the matching screws.
2.2. Screw on the hinged connector
Now screw the joint connectors (10) to both sides of the assembly (A1) using the hexagon screws included in the delivery.
3.1. Material for assembly A3
For building assembly A3, you need the aluminium profiles (08) as well as the right-angle connectors (10).
3.2. Drive the connectors into the tubes
Here too, apply adhesive to the tenons of the plug connectors and drive them into the aluminium profiles with a plastic hammer. The assembly (A3) is finished.
4.1. Assemble assembly (A4)
To assemble assembly A4, we take 2 elements of assembly (A3) and the remaining square tubes (09) and again fit them together by driving them in. Assembly (A4) is now finished.
B: Fully assemble plate supports by connecting the assemblies
1.1. Material for the panel supports
1.2. Drive assembly (A2) into the profiles
1.3. Drive in assembly (A3)
Now drive the remaining assemblies (A3) into the opposite opening of the two lower profiles.
1.4. Drive in assembly (A2)
Now drive the remaining assemblies (A2) into the two remaining openings of the profiles.
1.5. Drive in assembly (A4)
1.6. Finished panel support module (E2)
Step 3: Fully assemble the panel cart from Module E1 and Module E2
Assemble Module E1 and Module E2
Parts list – products from our online shop:
Item | Name | Variant | Item no. | Quantity |
3 | Aluminum profile 2 webs 15 mm external angle | Length: 860 mm, Cutting diagram: A | R-2ST-WA-SI | 2 |
14 | Aluminum profile without web | Length: 483 mm, Cutting diagram: A | R-V25-SI | 2 |
For the construction of the frame or structure, the connectors are simply tapped into the aluminum profiles. In this way, all conceivable substructures for advertising signs can be easily realized. And by using special joint connectors, even triangular frame structures are possible.
1. Place modules (E2) onto module (E1)
Insert module E2 flush against the web ends of module E1
2. Screw modules (E2) to module (E1)
Screw together on both sides at the holes of the webs
3. View of the rear screw connection
4. Fix the panel supports with the L-profile (03)
Screw the angle profile (03) with screws (14) from below onto the outside of the chassis frame and to the joint connectors
5. Screw module (E2) to (E3) from the inside
Screw the support structure firmly to the chassis from the inside
6. Tighten the hinged connector screws
7. Screw the stabilising panel on at the back
8. The panel trolley is finished
The materials from our range
The completed DIY custom panel cart
The fully assembled ALUSTECK® Professional Panel Cart
Technical Data ALUSTECK® Panel Cart:
Height: approx. 1,380 mm, Depth: approx. 535 mm, Width: approx. 910 mm,
Weight: approx. 10 kg.
Areas of Application and Advantages of a Panel Cart with ALUSTECK®
Industries:
- Advertising Technology
- Logistics
- Exhibition and Shop Fitting
Suitable for storage and transport of the following panel materials:
- Alu-Dibond
- Wooden panels
- Plastic panels
At ALUSTECK® you order the material for your project like a kit, directly configured to your desired dimensions:
Material, Tools and external accessories for the construction of the panel cart
Tools:
- Cordless drill
- Metal drill bit 4 mm
- Plastic hammer
- Center punch
- Screwdriver
- Circular saw or jigsaw for cutting the panels
- Folding rule or tape measure
Required external accessory material from stores:
- Alu-Dibond panels as stabilizer
- Cyanoacrylate-based adhesive
Products for building a panel cart
Simply configure materials for your kit online!
Adjustable foot Swivel castor with brake / Ø 50mm Appliance castor Castor with brake Ø50mm
€4.95*
€4.95*
Connector 25×25 Swivel Joint Connector, 45 to 195 Degrees Adjustable, 25x25mm Push-fit Connector for Square Tube Swivel connector 45–195° €4.16*
Variants off €3.78*
From €3.78*
Connector 25×25 Right Angle 25x25mm Connector Square Tube Right angle €2.86*
Variants off €2.57*
From €2.57*
Online cutting service:
Profiles cut to size! 955mm
Profiles cut to size! 955mm
FAQ: Build your own panel trolley – building guide with ALUSTECK®
The load capacity depends on the choice of material for the profiles, the connecting elements and the castors. Reinforcement with cross braces can further increase stability.
Yes, with ALUSTECK® you can extend or adapt your model at any time. Thanks to the flexible plug-in system, additional elements can be integrated easily.
As a rule, a rubber mallet is enough to insert the connectors. A cordless screwdriver can be helpful for screwing on castors or reinforcements.
Yes, the aluminium profiles from ALUSTECK® are corrosion-resistant and weatherproof. This makes the panel trolley suitable for damp environments or outdoor areas too.
Hard castors are ideal for smooth floors, while pneumatic or soft rubber castors are better suited to uneven surfaces. A combination of swivel and fixed castors improves manoeuvrability.
In theory no, but the size should be matched to the load capacity of the profiles and castors. For very large models, additional reinforcements are advisable.
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All projects and information are for inspiration only. We do not provide any legally binding information regarding construction and implementation. All constructions you undertake with ALUSTECK® are your responsibility. Please check your construction yourself accordingly for statics and correctness.
For the information mentioned above, ALUSTECK® assumes no liability or warranty for the correctness of the construction, for statics and the usual wear and tear of the goods, as well as defects or damages of any kind resulting from incorrect application or negligent handling or operation or extraordinary use.
