Hi all. Hope this community is reasonably active. I plan on building the kayak cart shown on this site but with some modifications. I'll need to change the overall height and width but that is easy enough. The biggest change will be using 16 inch balloon wheels linked here https://www.amazon.com/dp/B0H292WVYQ

These wheels have a 26mm (1.024") axle bore so I am running through my options to adapt the kart kit for these wheels. I am sort of assuming they are intending a 1.00" axle.

One possibility would be to change the entire frame to 1" EMT and fittings. The ID of 1 inch EMT is 1.049" so a 1 inch axle would fit inside the EMT tube. I am somewhat concerned that the cart's weight would be significantly more if I go this route.

If there was a 90 degree fitting for the axle that was 1" where the axle goes through but 3/4" for the vertical tubes, then just the axle could be 1" and the rest of the frame 3/4" but I don't see such fitting as available.

Another class of options would be stay with 3/4" frame (using the current kit parts) and adapt the wheels for a smaller axle. There are various ways to do this. One way would be to press actual ball bearings into the wheels. A another, maybe simpler way, would be to put bushings over the 5/8" threaded rod with 1" OD for the wheels.

Just interested in options here and maybe someone has already build a version wheeling having a 1" axle.

I need to settle on the axle design because I don't want to buy bother 3/4" fitting and 1" fittings. Also, I am not sure I love the ide of the threaded rod for the axle. That adds a lot of weight but allows using regular nuts to attach the wheels. Most of the commercial carts use , smooth tube for the axle and the wheels are attached with quick release lynch pins. I kind of like that concept better.

I was also looking in EMT material. I see the standard stuff is steel. I'll be operating and storing the cart in a hot, humid location near the ocean so corrosion is a concern. I saw that aluminum EMT is said to be available but maybe not easily obtained. I am interested in other thoughts about corrosion resistance.

A little background info for context: I am an engineer with above average mechanical skills. I can run lathes and mills but don't easily have access. A lot of the solutions might require machining custom parts but I'd like to minimize needing that.