Hitch-mounted Surf/Pier/Fishing Cart for Fishing on the Beach

Packing for the beach usually means sacrificing valuable truck bed space for a bulky surf cart. I wanted a heavy-duty cart that could carry all my gear, roll smoothly over deep sand, and plug directly into my truck's hitch receiver for travel. Starting with an aluminum Harbor Freight cargo carrier, I fabricated the ultimate dual-purpose surf and pier fishing cart.

For the complete, step-by-step breakdown and in-depth design details, check out the full article over on Reckonill.

If you like making your own fishing gear, this No-Weld Aluminum Sand Spike is a key component of this cart.

Disclaimer: This project is presented for educational and demonstration purposes only. Any modifications, alternative material selections, or use of this guide for your own builds are done entirely at your own risk. Always follow safety precautions when working with power tools or customized equipment.

Note: Some of the links below may be affiliate links. If you make a purchase through them, I may earn a small commission at no extra cost to you, which helps support future DIY builds!

Materials

1. Haul-Master 500 lb. Capacity Aluminum Cargo Carrier
2. M6 x 20mm x 60mm Stainless U-Bolts (2) (for 5/8" axle)
3. M6 x 25mm x 70mm Stainless U-Bolts (2) (for 1" axle)
4. Bonnlo Balloon Wheels 16" (25mm bore)
5. 1" Aluminum Round Bar (39-1/4")
6. Quick Release Pin, Diameter 3/16"
7. 1/4" PTO Pin (2)
8. 1.5” Aluminum Square Tube, 1/8"
9. 1" Aluminum Square Tube, .0625"
10. 1/4-20 x 1-1/2" Stainless Flat Head Hex Socket Cap Screws (2)
11. 1/4-20 Inch Nylon Inserted Self Locking Nuts
12. 5/8 or 3/4" Aluminum Round Bar (15")
13. Aluminum Round Tube 2" 0.065 wall; 9" (6)
14. 1/4-20 Hand Knobs
15. Sand Spike (3) - Designs created in Autodesk Fusion
16. 1/4-20 x 3-1/2" Stainless Flat Head Hex Socket Cap Screws Bolts (6)
17. 1/4-20 x 1-1/4" Stainless Flat Head Hex Socket Cap Screws Bolts (6)
18. 1/4-20 x 1-3/4" Stainless Flat Head Hex Socket Cap Screws Bolts (6)
19. 1/4-20 Stainless Hex Nut
20. Red Thread Locker
21. M8 100mm Star Bolts (2)
22. M8 Flange Nuts (2)
23. JB Weld (if you can't weld on the flange nuts)
24. 8mm x 40mm Lock Pins

Autodesk Fusion Designed 3D Models

1. 5/8" Fishing Cart Axle Spacer (3D Print)
2. Hub Bushings for 20mm Hub Beach/Balloon Wheels (3D Print)
3. 3/4" Round Tube Handle for Beach Cart (3D Print)
4. 1" Square Tube "Kickstand" for Beach Cart (3D Print)
5. 1.5" to 1" Telescoping Square Tube End Cap (3D Print)
6. 1/4-20 Nyloc Knob/Star Nut (3D Print)
7. 1/4-20" Low Profile Star Knob (3D Print)
8. Low-Profile M8 Knob (3D Print)
9. M8 Nylon Washers (3D Print)

Tools

1. 3/16", 1/4", 21/64" Drill Bits
2. Cordless Drill
3. JB Weld (if not welding)
4. 35/64 Step Bit (for widening through holes)
5. 5/8" (or) 3/4" Step Bit (for handle through hole)

Fully assemble and square up the Harbor Freight cargo carrier, then fabricate your axle by cutting a 1-inch aluminum round bar to 39-1/4 inches and drilling 3/16-inch holes at both ends to accommodate the quick-release lynch pins.

Position the axle over the frame's rear crossmember, drill 1/4-inch mounting holes, and bolt it down using M6 U-bolts with metal backing plates, then slide on your 2.5-inch PVC spacers, balloon wheels, and lock everything in place with lynch pins.

Bolt a drilled 1.5-inch aluminum sleeve to the front center rail of the cart, then fabricate an adjustable kickstand and a bent 1-inch pull handle with a round bar grip, using nesting tubing and pins to lock them at your desired height.

Cut 2-inch aluminum tubing into 9-inch sleeves, drill mounting holes with widened outer access points, coat the rims in Plasti-Dip to protect your rods, and bolt them securely to the cart's vertical frame rails.

Drill mounting holes along the cart frame for the sand spikes (how to make the sand spike), slide a 1/4-20 x 1-3/4" screw through from the inside out, secure it against the frame using red Loctite and a standard hex nut to create permanent threaded studs, and then slide your sand spikes over the studs to lock them down with threaded star knobs.

Lay the long steel hitch tongue bar across the bottom of the cart to scribe the frame rail overlap, drill two 21/64-inch holes through both the bar and the frame, strip the zinc coating from steel M8 nuts by soaking them in white vinegar inside an ultrasonic cleaner for 15-20 minutes.

Temporarily super glue the nuts over the drilled holes before tack welding or cold-welding them with JB Weld to the frame, and finish by wire brushing the welds, spraying with black rust-preventative paint, and mounting the assembly to your truck's hitch using M8 x 100mm star bolts.

By building your own, you get a bombproof cart that carries all your rods, handles deep sand with ease, and plugs straight into your vehicle's receiver hitch without taking up an inch of cargo space in your truck bed.

If you decide to tackle this build, be sure to hit the "I Made It!" button below and share your photos! For advanced design notes, 3D printing files for custom spacers, and more detailed instructions, head over to the original post on Reckonill. Happy fishing!