EasyTravel

Construct a flexible store cart

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Synopsis: There are plenty of ingenious particulars to this store cart. The highest is designed to tuck below the lengthy rails, which permits measuring instruments, drawings, or a pocket book to sit down on high whereas boards can nonetheless be stacked throughout the rails. The ends of the highest are open for simpler cleansing. The rails have recesses for small gadgets like ear plugs and pencils. The wheel association permits for optimum maneuverability in tight areas.


A store cart is a godsend for milling. Holding planks or elements when you’re jointing and planing, it serves like a pair of sawhorses on wheels. End jointing and also you simply roll the stack to the planer, then to the router desk or the mortiser. Mine additionally will get wheeled into the bench room, the place area is so much tighter. In there it provides me a number of ranges of storage for the elements and clamps and instruments I need proper at hand, permitting me to maintain the bench away from litter. I made my first store cart 30 years in the past, after studying Jim Tolpin’s e book Working at Woodworking (1991, The Taunton Press). Since then, I’ve made a number of others; that is my newest.

Store Cart Building

Shop Cart Construction Diagram

Recess time. Before assembling the cart frame, Boggs routs recesses into the top long rails. They will hold pencils, drill bits, earplugs, and other small items while still allowing boards to be placed across the rails.
Recess time. Earlier than assembling the cart body, Boggs routs recesses into the highest lengthy rails. They’ll maintain pencils, drill bits, earplugs, and different small gadgets whereas nonetheless permitting boards to be positioned throughout the rails.

Taken for a spin. The cart’s wheel arrangement, with swiveling casters centered at the front and back, enables it to turn on a dime and negotiate tight shop spaces. Yet its fixed side casters keep it tracking straight when you want it to.
Taken for a spin. The cart’s wheel association, with swiveling casters centered at the back and front, allows it to activate a dime and negotiate tight store areas. But its mounted facet casters hold it monitoring straight if you need it to.

I made my earlier cart with double tenons, however this time I made a decision to affix the body elements with machine screws and epoxy. It’s faster and really robust. I designed the cart’s high to tuck below the lengthy rails, which lets me place measuring instruments, drawings, or a pocket book on the highest whereas nonetheless stacking boards throughout the rails. The lengthy rails have recesses routed out that I take advantage of for pencils, ear plugs, and different small gadgets. By finding the top rails under the highest, I saved the ends of the highest open, making it straightforward to brush it out, an ideal assist in retaining the cart clear.

Two shallow drawers give me fast entry to my important measuring and format instruments, a pocket book, and ceaselessly used bits and fasteners. Merely however sturdily made, these drawers, that are facet held on runners, open easily and will be accessed from both facet of the cart. You possibly can add a spring-loaded cease to maintain the drawers centered when they’re pushed in, although I haven’t discovered it needed.

On each ends of my earlier cart I screwed on a crosspiece midway up the legs; I can lay lengthy elements or planks on these whereas retaining the underside floor obtainable for different gadgets. I haven’t added crosspieces to this cart but, however when I’ve a free hour, I feel I’ll.

I’ve realized from expertise how vital wheel choice is. I purchased low cost metallic wheels for my authentic cart and all the time hated them. All 4 had been swivel casters, so it was laborious to maintain the cart rolling in a straight line. However they labored simply properly sufficient that I by no means received round to altering them.  

For this cart, I purchased two mounted wheels and two swivel wheels, all 5 in. diameter with inflexible rubber tires. Bigger-diameter wheels roll so much higher and stop particles on the ground from stopping the cart in its tracks; with these wheels I may even roll over an extension twine.

Cart body meeting

Epoxied screw joinery

Epoxy provides this joint its long-term energy, however the screw’s threads pull the elements collectively at glue-up. The shallow pilot gap on the backside provides buy to the screw threads.

Epoxied screw joinery diagram

Pre-cut threads. With one pair of legs and long rails clamped on a flat surface, Boggs first drilled clearance and pilot holes and cut a countersink, and then, as shown here, he drove a bolt dry to pre-cut threads in the pilot hole.
Pre-cut threads. With one pair of legs and lengthy rails clamped on a flat floor, Boggs first drilled clearance and pilot holes and minimize a countersink, after which, as proven right here, he drove a bolt dry to pre-cut threads within the pilot gap.
Start spreading the glue. Boggs uses an undersize screw chucked in a drill and dipped into epoxy to deliver adhesive to full depth in the clearance and pilot holes. He also spreads epoxy across the parts’ mating faces. And before driving the real screw, he dips it into the glue as well.
Begin spreading the glue. Boggs makes use of an undersize screw chucked in a drill and dipped into epoxy to ship adhesive to full depth within the clearance and pilot holes. He additionally spreads epoxy throughout the elements’ mating faces. And earlier than driving the actual screw, he dips it into the glue as properly.

Do the tighten up. After driving the screw almost all the way with a drill, Boggs does the final tightening with an Allen wrench to get just the torque he wants.
Do the tighten up. After driving the screw nearly all the best way with a drill, Boggs does the ultimate tightening with an Allen wrench to get simply the torque he needs.

The association of the wheels can also be vital. On most carts the wheels are on the corners and the swivel wheels are each on the similar finish. For this cart I copied the diamond-shaped wheel sample of an previous dray, finding a hard and fast wheel on the middle of every lengthy facet and a swivel wheel on the middle of every finish. This association permits me to maneuver the cart by tight areas and make very sharp turns. Actually, the cart can spin 360° with out going anyplace. If I wish to entry one thing in a drawer from the alternative facet, I can spin the cart whereas standing nonetheless. But the cart additionally simply tracks straight. One factor to learn about this wheel format is that when you’ve got a really heavy cantilevered load and it’s off stability, it might conceivably tip the cart and dump your elements. To stop that from taking place, I prolonged the legs on my cart to inside 3⁄4 in. of the ground; if the cart ought to start to tip, the legs would cease it.

How massive ought to your cart be? Nicely in fact that is determined by the scale and association of your store. I made mine 24 in. by 44 in., however in a small store that is perhaps too massive. I like to recommend chopping a bit of plywood to the scale you think about your cart’s high to be and inserting that on a tall cardboard field. Put this mockup anyplace within the store you assume you would possibly use your cart. It’s best to be capable of determine an acceptable measurement fairly shortly.


Versatile Shop Cart Sprd ImgBrian Boggs (brianboggschairmakers.com) rolls his store cart in Asheville, N.C.

From Nice Woodworking #300

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