Building The Penultimate Pulk Sled

Parts

#2 Spur Grommet Die Set Installation Tool ($30.00)
 
#2 Spur Grommets - Nickel - Qty 25 (enough for 2 sleds) $7.25
 
#2 Spur Grommets - Stainless Steel - Qty 6 (optional ) $6.00
 
Shipping is about $10.  I used 4 stainless steel grommets on the sled for a little added strength. Nickel is actually nickel plated brass, which looks nicer and doesn't corrode compared to brass alone. Nickel is better for the belt because it is lighter.
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Stainless steel grommets are a little cheaper at Aerostore ($0.80 instead of $1.00) but you'd pay another shipping cost.
 
2" Seat Belt Webbing - 5 feet per belt - $3.00  (get extra!)
 
1" Seat Belt Webbing - about 5 feet - $1.80
 
The seat belt webbing slides through the buckles more smoothly, and is easier to tighten. My second choice is the polyester webbing, which comes in pretty patterns as well. If the 1" Seat Belt Webbing is out of stock, try 1" Polyester Webbing.
 
Double Adjusting Side Release Plastic Buckles You need a 2" ($1.76) and 1" ($1.02) buckle. Get extras too.
 
Speedy Stitcher Sewing Awl - $10.95 - This is optional. I used it to sew the end of the belts over to keep them from coming out of the buckles. It includes a large spool of heavy thread.
 
Blackhawk Belt Pad Small, Medium, or Large.
$17 for Medium, which fits almost everyone.
 
The back of the belt pad sticks nicely to the hips so it doesn't rotate or slip down. The seat belt webbing does slip on the belt pad, but this is easily fixed by frizzing up the back of the webbing with sandpaper. The belt buckle should be just below the belly button so you're pulling with the pelvis. If you have the belt too low and tight, it can compress the femoral arteries and reduce blood circulation to the legs. The clue that this is happening is that it's really hard to pull the sled, but you're not winded.
From REI.com (Also available in the stores)

BlueWater 4mm Utility Cord - 30 ft. $7.50 - Used for the sled end of the poles.

BlueWater 3mm Utility Cord - 50 ft. $9.95 - Used for the belt end of the poles and for lashing the duffel bag to the sled.

REI Classic Duffel XXX $49.50 - I bought this on clearance for $25. It works great, but you may find something cheaper elsewhere, or just use a plastic tarp wrapped around your gear.

Nite Ize Figure 9 Tent Line Kit - Package of 4 $10 - I use these with the 3 mm cord to quickly tie the cargo to the sled.
From Hardware Store
 
#10 Stainless Steel - 1" machine screws - nylon lock nuts - 1" fender washers - Quantity 8 (for runners - plus 1 or 2 extra)


#8 Stainless Steel - 3/4" flathead screws - Quantity 4 (for poles - 
note: 11/64" clearance hole in pipe - 9/64" guide hole in pole)

4 feet 1/2" x 3/4" aluminum angle (1/2"x1/2" is OK too)

1/2" Fiberglass fence posts - 5 feet - quantity 2 (plus extra) - about $3 each. If you can't find them locally, or you want them longer to be sure the sled doesn't hit the back of your skis, try ordering 10 of the 1/2" 6-footers for around $45 (with shipping) from Electric Horse Fence. They come in handy for other things too.

1/2" schedule 80 PVC pipe to glue to ends of poles for rope loops. You only need 2 or 3 feet at about 50 cents a foot. Schedule 80 has a smaller inner diameter that fits the pole more closely, and dark grey UV stabilizers so it lasts longer in the sun.

Devcon Plastic Welder glue, or equivalent (make sure it handles the cold).

3/8" Plain Grommet Kit - about $8 - I sharpen the punch and use it as a drill bit to make holes in the webbing for the spur grommets. You can also practice pounding in plain grommets while waiting for the spur grommets to arrive.



Paris Expedition Sled


REI is the best place to get them if you can't pick them up at a local store.



Also, Aubuchon Hardware in New England may have them in stores.
Emsco Heavy Duty Beast Expedition Sled (1138)

If you can't find the Paris Expedition, it looks like the Emsco Beast sled will work well too. I bought one in stock at Dick's Sporting Goods last year ($40 there now). I haven't modified it yet, but I think I can get 2 grommet on the outside, curved front corners, and 2 more on the forward bottom corners.  I'll also try a single aluminum angle runner along the center of the sled in back, if needed (and it probably will be on steep trails).

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