So this is my current lumber storage cart. It’s huge - I built it a couple years ago
and I actually have free plans available - but as you can see, it’s gotten a little out
of control. I don't know why, but I hold onto every little piece of scrap wood that I have
and put it in this cart. But, it’s just taking up too much room. So today, I’m going
to build a more compact version of this (I’ll also have plans available). So, let's get
to it!
We all know how expensive lumber is nowadays and plywood is no exception. That’s why
my first consideration when designing this lumber cart was to make sure it could be built
using a single sheet of plywood. I had my sheet cut in two lengthwise at the store,
so I could fit it into my SUV. The plans are actually designed in a way that you can have
the sheet cut into smaller sections if you need to do that for easier transportation.
I’ll use my track saw to break down the plywood, following the cutting diagram in
the build plans. If you’re interested, you’ll find a link to the plans in the description
down below. Now, if you don’t have a track saw, you can make a simple guide for your
circular saw. I used this method when I built my previous lumber cart, back when I didn’t
have a track saw. I’ll also leave a link below to an article on my website that explains
how to build this simple guide.
The sides of the cart are slanted on an angle.To make the diagonal cut, I’ll measure and
mark both sides then connect those with a T-square. I can then use my track saw to make
the cut. If I did my math right, both sides should come out perfectly symmetrical.
With that done I’ll continue to break down the second half of this plywood sheet, and
finally finish off by making the smaller cuts on my table saw and miter saw.
It’s a good idea to label the parts as you go to avoid any confusion. I now have all
my parts cut to size, and a few small pieces leftover. But I have something planned for
those pieces too, so be sure to stick around until the end for the bonus feature.
My goal is to make this lumber cart as simple as possible. A single sheet of plywood and
easy assembly using screws. Nothing fancy. The one exception I’ll make is to add a
few dados in the center partitions so I can easily slide in the dividers.
Now, you can clamp down a simple fence and run your router along the edge like I did
back when I made my previous lumber cart, or you can build a really simple jig. If you
know me at all, you know I love making jigs, especially if they make your life easier!
I’ll use the edge of the plywood (which I first checked for square) so I can attach
these scrap pieces into an L shape at 90 degrees. I’ll check again for square, and make a
matching pair.
To make the dados I’ll use an undersized plywood bit and set the depth using this height
setting gauge. Here I’m just using a piece of scrap to run the router through and make
a reference in the jig. Now I can drop the jig into place and line up the edge of the
reference dado in my jig with my layout lines, then clamp it down. I’ll then drop in the
router to make sure the spacing is right and clamp down the opposite side.
A small but useful tip is to make sure you’re running your router with the ejection port
facing the back. It’s a lot messier but it will prevent clog-ups with the chips ejecting
to the back instead of in front of the router. I had my router facing the other way at first
and it would get stuck before I reached the end because of all the dust getting in the
way.
Again, I’m using an undersized plywood bit for this. You can use a ¾-inch straight bit,
but it might be a bit too big given that plywood is always slightly less than three quarters.
That’s why they make these specialty bits. I’ll leave a link below if you want to check
it out.
At this point I always worry that I messed something up but I’m glad to see that all
the dados line up perfectly. That means it’s time for assembly!
As I mentioned, I’m keeping assembly simple using nothing but screws. Screwing into plywood
blindly can be challenging, but can easily be overcome by tracing a few basic layout
lines beforehand. And by the way, these dimensions are all included in the plans.
Oh, I almost forgot to cut the tips off the top of the diagonal sides. Do I have to do
this? No… but, they’re sharp and it’ll just look better.
I’ll start by securing the bottom panel to the sides. And if you’re wondering, I’m
not using any glue. Screws are plenty strong and it’ll just make it easier if I want
to take it apart one day and repurpose the plywood. I’ll simply first drill some pilot
holes using a countersink bit along my layout lines, then drive in the screws.
[Sound effects]
Here the panel wouldn’t fit so I just loosened the screws to give it a little wiggle room.
[Sound effects]
After installing the front and back pieces, I’ll drop in the partitions and use a scrap
piece of MDF as a spacer to accurately position the middle panels.
[Sound effects]
Looking good, all that's missing is the dividers. I’ll slide them into the dados then mark
the angle I need to cut. But, just when I thought things were going so well, I noticed
that the front divider was too small. I don’t really have any extra plywood to spare so…
I came up with a quick fix that no one will notice. I set my table saw fence to match
the thickness of the plywood, then ripped a thin strip of poplar I picked out of my
old lumber cart. I’ll apply a little glue, then secure the strip to the edge with some
blue tape. Once dry, I can trim the ends and sand it nice and flush. Once in position,
no one will be the wiser.
Okay, now that that's fixed, I can just mark where the divider meets the partitions. I’ll
then remove it and connect the lines with a ruler, then make the cut with my track saw
- or you could use the miter saw by playing around with the angle until it lines up. And
voilà.
Like everything else in my shop, I want this cart to be mobile. I ordered these 4 inch
swivel casters from Princess Auto, 2 of them locking. They can handle 180 lbs a piece,
which should be more than enough for this small cart.
Given the compact size of this cart, you’d be surprised how heavy it is! When you think
of it, it’s a full sheet of plywood despite its small size, so not as light as I was expecting
at this particular moment. Yeah, I got this.
Old lumber cart: meet new lumber cart. You can’t really tell from this angle, but the
new cart is less than half the size of my old one. It’s only 2 feet deep by 28 inches
wide. But nevertheless, don’t worry, it can hold plenty of lumber. I always find myself
keeping these tiny little scraps and they always seem to come in handy. You can use
plastic bins in the bottom cubbies like I am or just use the horizontal storage as is.
[Sound effects]
All right, I’ve managed to transfer everything I had except for these panels. But- I think
I have an idea for that. I have all these offcuts left from my sheet of plywood so I’m
going to build a little sidecar attachment. If you have the extra space, it can be easily
mounted on the side or on the back using pocket screws. Just be mindful of the screw placement.
[Sound effects]
It’s time to say goodbye to the old lumber cart… You’ve served me well! If by any
chance you have the space and you would prefer to build this lumber cart, I’ll also leave
a link to the plans below. So, out with the old… and mmm better clean this up while
I’m at it… Eventually I’ll paint that wall… and in with the new! Don’t forget
I have plans available for this compact lumber cart including the add-on side cart.
Until next time, thanks for watching! See you soon.