How to Make a Movers Dolly

Buy a piece of plywood and cut it to a size of 18 inches by 32 inches. Cut the 2-by-4s into four sections, with two pieces being 32 inches long, and the other two being 18 inches long. It is possible to request pre-cut boards at some hardware stores.

Put each of the two pieces of 32-inch 2-by-4s under your plywood. Place them at opposite ends of the plywood, under the sides also measuring 32 inches each. Screw them onto the base of the plywood. This makes your frame more stable, especially when pulling heavy loads, and prevents damage to the dolly's wheels and screws due to absorbing too much force. Put the other two pieces of 18-inch 2-by-4s on opposite sides of the plywood, on the sides measuring 18 inches. This time, place them on top of the plywood. This will be the primary surface on which heavy loads are placed. It will also make your frame more stable. Temporarily assemble the 18-inch 2-by-4s together (without screwing them onto the plywood yet) to see if everything fits well.

Cut an indoor/outdoor carpet to a size that will cover the entire surface of the 18-inch by 32-inch plywood. Cut another two identical sets of indoor/outdoor carpet to a size fitting the 18-inch 2-by-4s that were placed on top of the 18-inch blocks of plywood.

Glue the carpet onto the plywood. This carpet serves as padding that protects items moved on the dolly from scratches. Aside from protecting finishes, the carpeting also makes it easier to slide things onto the dolly. Cover the two pieces of 18-inch 2-by-4s placed on top of the plywood entirely with carpet as well (including each one's sides and bottom).

Drill two 1/2-inch holes apiece on each side of the now carpet-covered 2-by-4s placed on top of the plywood. You will drill a total of eight 1/2-inch holes: two on each separate side of every 2-by-4, meaning four on each 2-by-4 (two each on the left and right sides,) to completely secure the 2-by-4s onto the plywood. As a guide measurement, each drilled hole should be about 1 inch away from the outer border of each 2-by-4.

Drill straight until you make a hole into the plywood just deep enough to screw the 2-by-4s and plywood together. Screw them together to make permanent attachments.

Drill two 1/2-inch holes on the opposite sides of one of the 2-by-4s, about 3 to 4 inches away from each end. Insert a 6-foot length of rope through the holes on top, with one end of the rope going into one hole, and the other end of rope going into the other hole. Tie each end of the rope found under the plywood into a knot to prevent the ends from coming back up through the hole. You may put some adhesive on the rope's knots to keep them from coming undone. The rope will help you pull the dolly.

Turn the frame upside down and drill four holes in each corner of the plywood (upper-right, lower-right, upper-left and lower-left) where you will screw each of the four 3-inch hard rubber swivel casters. Drill one hole each for each caster about 3 inches from each outer border of the plywood. This distance enables the dolly to tilt and move around more efficiently. Attach the casters to each hole and secure with screws.