Plywood Lumber Cart

I saw this pic during a search on Google Images for Plywood Lumber Cart.

I figured I could repurpose my old Table Saw Cart, that I had originally used to get my table saw to the same height as my workbench, when my workbench was used as an outfeed table.  I since moved my table saw and am now designing/building a new outfeed table for it.  

This lumber cart is pretty robust. I thought about extending the base so it could support more boards, but instead I just attached some small pieces with screws as lips to prevent the pieces from falling off. By not gluing the lips I have given myself the option of extending the base sometime down the road if I ever see a need. Right now the cart will support 14, 4×8 ft sheets of 3/4-inch thick plywood.

I first made a template using 1/8” thick hardboard. I used the template to trace on the 2 layers of plywood that I had glued together. I cut out the pieces using a jigsaw and then screwed the template on top of each piece and used the router table to get them to the same profile. Lesson learned, use a thicker piece than 1/8” think material when used as a routing template. Then I made a jig so all of the recesses were the same width and thickness. I cut the depth too much so I glued in 1/8 in thick hardboard so the plywood strips would be proud of the supports, so the 1st piece of lumber placed could glide along the supports and not get hung up.

I had used these heavy duty caster wheels, but they don’t have them available anymore. I look forward to using this plywood lumber cart and hope it helps me keep the shop in better shape.

-- You can't fail if you don't give up.