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Lift Table Frame
The lift table frame extends the lift table top to better support the telescope, provides guide boards to keep the Hinged Telescope Support Board from sliding sideways, and has a locking brace to keep the tele from rolling off the lift table while moving the telescope.
( photos above) Cut 2 1x2s that extend across the front and back of the lift table top. Cut the extension from 1/2" plywood. Cut it the width of the table top, and 5-1/4" long. Cut 2 2x2s that extend from the front edge of the front 1x2, over the cart top,over the rear 1x2and to the rear end of the extension. You do not need to bevel cut the ends of the 2x2s. (picture is incorrect)
Place the casters on the table top corners, flange down, so they are 1" from the sides of the table top. Put the 2x2s lengthwise on the table, between the casters, and touching their flanges. Bolt the 2x2s to the front and rear 1x2s with 3-1/2" #10 machine screws, with a washer on top, and 1-1/4" fender washer and stop nut on the bottom. (The fender washers hold the frame down on the metal lift table top.)
DO NOT attach the castors yet, we'll do that later!
With 2" casters, the hinged support board will drag on the bolts supporting the extension when moving the tele to or from the vehicle when the connector is not perfectly level. To prevent that, use 2-1/2" casters, or countersink the bolt heads and washers on top of the 2x2s that support the extension, as shown in the center picture above. Use a spade bit to countersink.
Bolt the extension to the 2x2's with 2 2-1/2" 1/4" bolts close to the metal top, and 2 4-1/2" bolts near the end of the extension. The bolts at the end of the extension are 4-1/2" long, because they also attach 2 2x4s that are 6" long, and that stick out 3-1/2" past the end of the extension. These will support the connector board (described later).
We'll mount the casters on the support board later.