I-Beam Trolley Plans – 2 Ton, Build It DIY

Description

A good, strong I-Beam trolley is a must for a gantry crane.  That is what you will get when you build a 2-Ton Trolley from these plans.

2-Tons (4000 lbs) is no joke.  We offer Gantry Crane Plans to lift that load, and now a great trolley to match.  This is not a sketchy design like some you may find online.  See how we designed it.  This is a lighter version of our 3-Ton trolley, with a very similar design, and the same main goals:

1. An overhead I-Beam trolley to carry a true, full 2-Tons.
2. A Trolley you can build (and repair if needed) with mostly off-the-shelf parts.
3. Wheels spread farther apart to distribute load better along the I-Beam flange.
4. Minimize headspace requirements under the beam.

Yes, there are many inexpensive 2-Ton I-Beam trolleys online.  We won’t dis those, but we want one that does better.  Most important, we want super smooth rolling, which meets the goals above.  Plus, building is awesome when we can build one better than what we can buy.

This gantry crane trolley is designed for builders who want strong, reliable tools rather than a disposables.  Build it yourself, better.

2-Ton I-Beam Trolley Key Features

• 2 Ton Trolley (4000 lb) capacity.
• Works with Standard I-Beam sizes from 5″ to 10″.
  (Not for use with H, W, or M beam profiles.)
• Off-the-shelf rollers and hardware.
• Wide wheel spacing for better beam load distribution.
• Low headroom design.
• No welding required.

Plans include the detail drawings, easy to follow instructions, DXF files for the parts that need to be cut-out, and tips for success.  Plans are available to download right after payment.

A perfect accessory to go with one of our Gantry Crane Plans.  Good luck with your project.

Specifications

I-Beam Trolley Plans – 2-Ton Capacity

• All Steel, high strength design.
• Works with both Steel and Aluminum I-Beams.
• Made with off-the-shelf rollers and hardware.
• Side plates have thickness options using high strength steel.
• Side plates have UHMW guides to avoid scraping the I-Beam.
• Rated capacity of up to 4000 lbs (2 tons), yet it also works perfectly with lighter loads.
• The design is adjustable to fit the specific I-Beam size of your gantry crane – 5″ to 10″ standard I-Beams.  (Not intended for H, W, or M beam profiles.)
• Made specifically to go with one of these Gantry Crane Plans. – Mobile Size (original), Garage Size for max fit in your garage, and the larger Upsize with many size options.
• Plans include detailed drawings with tips, notes, instructions, and a full materials list.
• DXF files for the side plates and guides are also in the plans download.
• Not for lifting people.

More About The Design Features

2-Ton I-Beam Trolley To Build From Plans

If you have looked for an I-Beam trolley, then you know there are many – and some are questionable.  After doing all the engineering for the 3-Ton trolley, I am now more concerned about labels for capacity on inexpensive trolleys online.

Here are the goals we set for this design:

1. Design a trolley for a true 2-Tons.  Not just to advertise a big number, but to actually perform with that full load.  (Of course it also takes a heavy duty crane as well.)
2. Make the I-Beam gantry crane trolley with mostly off-the-shelf parts.  Things like rollers that can be replaced rather than throwing away the whole trolley if I damage a wheel.
3. Build an I-Beam Trolley that is more stable, with wheels spread farther apart to distribute load better on the I-Beam.  Most gantry cranes have a straight I-Beam, so they do not need a trolley that will turn corners.  (Read the design study because the engineering on this point is interesting.)
4. Finally, minimize headspace that is required under the beam.  We want it close, but not to the extreme.

If you enjoy building things and want a strong trolley for your gantry crane, these plans will help you build a good one.

Limitations

1. Not the cheapest trolley.  It is strong, and meets the goals above, but you can buy cheaper units from Amazon.
2. This trolley is not intended for beams that turn a corner.
3. We offer the plans only, then you need to build it.

Construction

Most parts for this 2-Ton Trolley are standard off-the-shelf components.  We give McMaster.com part numbers in the plans, but you can also source the parts from a local supplier.  (That is what I did to save quite a bit of money on the big bolts and washers.)

The 2 side plates and the 2 guide pads require special cutting.  I chose water jet cutting because the plates I used are hardened 4140, which is really hard to cut by hand.  Water cuts right through the hardened steel.  I sent the included DXF file to my local water jet cutter, along with the hardened plate ordered from McMaster, then they cut-out the side plates for me.

I also like the water cutting because it is a cold process.  With plasma cutting, there is high heat near the cut which effects the material temper.  No issue with water cutting.

The actual trolley you see in the photos has the 3-Ton side plates and the 2-Ton Trolley main bolt.  The 3-Ton is very similar to the 2-Ton.  (The difference?  Material requirements are stricter, and the bottom bolt is larger on the 3-Ton.)

See the YouTube video about building the trolley for more information.  This is a perfect gantry crane enhancement.  Download the plans, then build it yourself.

Construction requires cutting steel tubes and plates.  Welding is not required.

Make the most of your new Shop Tools project.  We have plans, of course, plus these suggestions.

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