I-Beam Trolley Plans – 3 Ton, DIY

Description

Every good gantry crane needs a reliable trolley.  If you lift heavy items, this 3-Ton I-Beam Trolley is a strong DIY solution you can build from plans.

3-Tons is a lot of weight, 6000 lbs to be exact.  We already offer Gantry Crane Plans designed to lift that load, so why not build a trolley to match?  If you have looked at trolleys online, you know some designs are sketchy.  Not this one.  We set out with these goals:

1. We want an overhead beam trolley that will carry a true, full 3-Tons.
2. An I-Beam 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 under the beam.

We talk more about these topics in the accordion tabs below.

Yes, you can buy an inexpensive 3-Ton I-Beam trolley online.  That is not the point.  As an engineer I have loved some things and disliked other things about various trolleys, so I set out to build an I-Beam Trolley better than what I can buy.

In studying available trolleys, I was surprised how weak some of the designs appear.  Things you want to know, but wish you didn’t.  So, we made something better.  This DIY gantry crane trolley is designed for builders who want a strong, reliable trolley rather than a disposable one.  Plans are available to download right after payment.

Key Features:

• 3 Ton (6000 lb) capacity.
• Works with Standard I-Beams from 5″ to 12″.  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 easy to follow, fully illustrated instructions.

This is a perfect accessory for many variations of the Upsized Gantry Crane Plans.  Good luck with your project.

Specifications

I-Beam Trolley Plans – 3-Ton Capacity

• All Steel, high strength design.
• Works on Steel or Aluminum I-Beams.
• Rated capacity up to 6000 lbs (3 tons).  Works perfectly with lighter loads as well.
• Build it to fit the specific I-Beam size and gantry system you are using.
• 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.
• Not for lifting people.

More About The Design Features

3-Ton I-Beam Trolley To Build From Plans

If you have looked for an I-Beam trolley, then you know there are many options – but some are questionable.  After doing the design work on this one, I am even more concerned about true capacity on the inexpensive ones we see online.

For this design I set out to do a few things better than what you can buy.

1. First, I want a trolley that will carry a full 3-Tons.  Not just to advertise a big number, but to actually function under that load.  (Of course that takes a heavy duty crane to go with it.)
2. Second, let’s make a crane trolley that we can build with mostly off-the-shelf parts.  Things like the rollers that can just be replaced rather than throwing away the whole trolley because we can’t get replacement wheels.
3. Third, my cranes use straight I-Beams, so I do not need a trolley designed to turn corners.  I want an I-Beam Trolley that is more stable, with wheels spread farther apart to distribute load better to the I-Beam.  (Read the study about this because it is interesting how it turns out.)
4. Finally, I want to minimize headspace under the beam.  This is a double edged sword – but for me, reduced headspace requirements are important.  Not to the extreme, but definitely a strong consideration.

If you enjoy building things yourself and want a solid trolley for your gantry crane, these plans will help you build one better than most you can buy.

Construction

Most parts for this 3-Ton I-Beam 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.

The 2 side plates and the 2 scuff pads require special cutting.  I chose water jet cutting because the plates I used are hardened 4140, so it would be really hard to cut out by hand.  Water is amazing because it can cut right through the hardened steel.  I sent the included DXF file to my local water cutter, along with the hardened plate ordered from McMaster, and he cut them for me in about a week.

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.

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