SolidWorks© was used extensively throughout the project to model the cart assembly, track geometry, and manufactured parts. Existing and potential hardware was incorporated into assemblies to verify compatibility before fabrication. Drawings helped with machining operations and fastener selection.

York College’s machine shop provided the equipment necessary to manufacture the wheel assemblies used in the cart. Steel stock was cut to length, machined to final dimensions, drilled, and tapped to produce the final components. The use of calipers and edge finders allowed the assemblies to be accurately fabricated and in tolerance for the design.

After fabrication, the parts were assembled into the cart underbody structure. Four-wheel assemblies were constructed to be later mounted to a square steel tube frame using threaded fasteners. A plywood base was incorporated to create the cart platform and support continued frame construction. This stage verified component tolerances and assembly prior to final construction.

Following the creation of the wheel assemblies and underbody frame, the components were integrated into the final assembly. The assemblies were aligned and secured to the steel frame, while additional structural members were installed for support. Extra attention was given to wheel spacing to ensure proper alignment to the track. Upon completion, the cart was able to rest on the existing track system.

Initial testing revealed a higher amount of clearance between the side guide wheels and the track than expected. To improve their fit, larger cross-beams were fabricated and tested until an appropriate wheel-to-track spacing was achieved. Following validation of the new design, the existing track was deconstructed, and the taller, reprofiled track was constructed.