How to Build Your Own Golf Push Cart

Building your own golf push cart is a satisfying and surprisingly straightforward project that saves you money and lets you walk the course in comfort. This guide provides a detailed, step-by-step plan using common materials to build a sturdy, custom push cart you can be proud of. We'll cover everything from the initial design to the final custom touches.

Why Build Your Own Golf Push Cart?

While there are plenty of great push carts on the market, taking the DIY route has some distinct advantages. First, there's the cost. You can build a robust and functional cart for a fraction of the price of a mid-range store-bought model. Second is customization. You get to design it to your exact specifications - maybe you want an extra-large scorecard holder or a specific spot for your GPS unit. Finally, there's the simple joy of building something with your own two hands. It connects you to your gear in a different way, and rolling up to the first tee with a cart you built yourself is a fantastic feeling.

Phase 1: Planning Your Custom Build

Before you start cutting and gluing, take some time to think about the design. A little planning goes a long way and prevents headaches later.

Choosing Your Design

The most popular DIY design is the 3-wheel cart. It offers the best blend of stability and maneuverability, handling uneven terrain better than a 2-wheel version. Our guide will focus on a 3-wheel build, but the principles can easily be adapted.

• 3-Wheel (Tricycle style): The gold standard for stability. Two wheels at the back provide a wide, sturdy base, while a single front wheel makes turning effortless. This is the design we'll focus on.
• 2-Wheel (Pull Cart Style): Simpler to build but requires you to support more of the weight, similar to pulling rolling luggage. It’s a classic, but the 3-wheel push style is generally more ergonomic for walking 18 holes.

Material Selection: Keep it Simple

For a DIY build, accessibility and ease of use are priorities. This is why PVC pipe is the go-to material for most homemade push cart projects.

• PVC Pipe: It's cheap, lightweight, strong enough for the job, and incredibly easy to work with. You can cut it with a simple handsaw and join it with readily available primer and cement. We recommend Schedule 40 PVC with a 1.5” or 2" diameter for the main frame to get a good balance of strength and weight.
• Wood: Wood can create a beautiful, classic-looking cart but requires more advanced woodworking skills and tools. It's also heavier and will need to be properly sealed to withstand morning dew and rain.
• Metal: Using lightweight aluminum or steel might require welding and more specialized tools, but you can also assemble a frame using pre-drilled angle iron and bolts. It can be very durable but is often the most complex option for a first-timer.

Essential Features to Consider

Think about how you'll use the cart. What features are non-negotiable?

• Bag Cradle: How will the bag sit? You'll need an upper and lower support bracket to hold the bag securely. Simple V-shapes work perfectly.
• Handle: An ergonomic T-handle is easy to build and comfortable to push for a full round.
• Wheels: This is the most important component. Don't skimp here. Old jogging stroller wheels are fantastic because they are large and roll smoothly over grass. Alternatively, 10-12 inch lawnmower or utility cart wheels from any hardware store work great.
• Storage: How will you attach your bag? Plan on using bungee cords or adjustable straps. You can also add a small mesh bag or basket for headcovers, drinks, or a rangefinder.

Phase 2: Gathering Your Materials &, Tools

A trip to your local hardware store should get you everything you need for a PVC build. Here is a general shopping list to get you started. Dimensions can be adjusted for your specific bag and height.

Materials Checklist:

• PVC Pipe (1.5" Schedule 40): A 10-foot section should be plenty.
• PVC Fittings (1.5"):
  • (4) T-Fittings
  • (2) 45-Degree Elbows
  • (2) 90-Degree Elbows
  • (3) End Caps
• Wheels:
  • (3) 10-12 inch utility wheels. Look for ones with a simple hub that a bolt can pass through.
• Hardware:
  • (1) 36" long, 1/2" diameter threaded rod (for the rear axle)
  • (6) 1/2" washers (4 to go on each side of the rear wheels, 2 for the front)
  • (6) 1/2" locking nuts (use nylon-insert lock nuts so they don't rattle loose)
  • (1) 5" long, 1/2" diameter bolt, with a washer and a lock nut (for the front wheel)
  • (2) Bungee cords or adjustable straps
• Consumables:
  • PVC Primer and Cement
  • Sandpaper
  • Optional: Spray paint for plastic

Tools Checklist:

• Measuring tape
• Marker
• Hacksaw or PVC cutter
• Electric drill with a 1/2" drill bit

Phase 3: Step-by-Step Assembly Instructions

Here’s where the fun starts. Remember the old rule: measure twice, cut once. Before you use any glue, it's a great idea to "dry fit" all your pieces together to make sure everything lines up just right.

Step 1: Cut Your PVC Pieces

Using your hacksaw, cut your 1.5” PVC pipe into the following lengths. A simple miter box can help you get clean, straight cuts.

• (1) Main Upright: 30 inches
• (1) Handle Post: 6 inches
• (1) Handlebar: 18 inches
• (2) Base Frame/Rear Axle Supports: 12 inches
• (1) Rear Axle Housing: 20 inches
• (1) Front Fork Downrigger: 8 inches
• (2) Bag Cradle Arms (Upper &, Lower): 8 inches total (cut into four 4-inch pieces)
• (2) Bag Support Uprights (for upper V-cradle): 3 inches

Step 2: Building the Base Frame and Wheel Assembly

This is the sturdiest part of your cart, which will hold the rear wheels.

• Take the two 12-inch Base Frame pieces and drill a 1/2" hole cleanly through the center of both. This is for your axle.
• Take one of your T-Fittings and glue a 12-inch Base Frame piece to one end of the "run side" of the "T". Do the same for the other T-Fitting.
• Connect these two pieces with the 20-inch Rear Axle Housing piece in the middle by gluing it into the remaining T-Fitting openings.
• Take the two 45-Degree Elbows and glue them onto the ends of the two 12-inch pieces. This piece joins your axle housing to the main frame later on.

Step 3: Assembling the Upper Frame and Handle

The upper section comes together as two different modules.

• Take the 6-inch Handle Post piece and glue your third T-Fitting onto its top end.
• Glue the 18-inch Handlebar piece into the top of the T-Fitting to form your ergonomic T-handle.
• Glue the 30-inch Main Upright into the bottom of the T-Fitting below the handle.
• Now, assemble your "V-shaped" bag cradles. Take your final T-fittings and glue a 4-inch cradle arm into each side of the "T". This gives you upper and lower cradles for your golf bag.
• Glue the upper and lower cradles onto the Main Upright at a distance that best fits your bag.

Step 4: Putting It All Together

Now it's time to connect the two modules.

• Glue the open ends of the two 45-degree elbows from your Base Frame to the bottom of the Main Upright. This connects your entire frame into one large piece.
• For the front wheel, drill a 1/2" hole through the end of your 8-inch Front Fork Downrigger piece. Push the 5-inch bolt through, place a washer on each side of the wheel, thread on the wheel itself, and secure it with a locking nut.
• Glue the front wheel assembly into the bottom of the remaining T-Fitting at the base.
• For the rear wheels, insert the 36-inch threaded rod through the holes you drilled in the Base Frame pieces. Add a washer and a nut on the inside, slide on the wheel, add another washer, and secure it with a locking nut. Tighten them enough that the wheel has no wobble, but loose enough that it can spin freely. Glue the end caps on the exposed ends of the open pipes and rod for a clean look.

Step 5: Finishing Touches and Customization

This final step takes the cart from functional to truly your own:

• Spray Painting: Give your PVC cart a sleek finish with a spray paint designed for plastic. A matte black or silver can look very professional.
• Drink Holders &, Storage: A simple bicycle water bottle cage can be easily attached with screws. For more storage, consider zip-tying a small mesh bag to the frame.
• Scorecard Holder and Umbrella Holder: A small sheet of hard plastic or even a clipboard sawed to size and screwed onto the handle makes for a perfect scorecard holder. For an umbrella, a slightly wider section of PVC pipe mounted onto the handle with pipe clamps works wonders. Attach your bungee cords to hold the golf bag around the upper and lower cradles.

Tips for Success and Common Troubleshooting

Building something yourself is straightforward, but a few little tricks can make the experience even better.

• Dry Fit Before You Glue: Assemble the entire cart without using any PVC cement to make sure everything fits correctly. It's a lot easier to recut a piece of pipe than it is to pull apart a glued joint.
• Reinforce Joints: For added strength and peace of mind, you can drill small holes through the PVC fittings and the pipes and add a small nut and bolt through them for an extra layer of security.
• Choose the Right Wheels: Larger wheels (10" or more) roll more easily on soft grass and navigate bumps better. Smaller wheels can work but can get stuck in soggy turf or on small roots.
• Don't Skip the Primer: The purple PVC primer is important. It cleans and softens the plastic to create a much stronger weld when you apply the cement. Don't skip this step.