I built this materials cart a while back to clear up some space in my shop. The build is relatively straight forward starting with the base. I made mine from 2-4X8 sheets of 19/32” OSB and a couple of 2X4’s, some scrap ¾” plywood, and 4-3” locking casters.

 

Recommendations:

After building this cart and using it for a short while, here are a few recommendations on how I would make the cart better if I ever have to do it again.

• Use non-locking casters or only 2 locking casters in opposite corners. Even living here in earthquake country, I don’t think the casters need to be of the locking variety. It would take the “Big One” to make this thing move. If that happens, I’ve got bigger problems than figuring out how my lumber cart got moved. This would also reduce the cost slightly without affecting the functionality of the cart.
• Use 4” casters or larger. When the cart gets fully loaded, it is quite heavy making it a challenger to roll on the 3” casters that I used. 4” or larger casters would make it easier to roll, especially if you encounter a wood chip or power cord.
• Use 3/4” plywood instead of OSB if you can afford it. Placing screws on or near the edges would be more solid with plywood than with OSB.
• Install “handles” under the 3rd shelf from the top to aid in pulling cart. I did incorporate the recommendation into my cart after it was completed. It does make it easier to start rolling out of a corner of from against a wall.

Building the Base

I started the base by cutting 2×4’s to length for the sides, ends and middle supports. The middle supports help to keep the base OSB from sagging when the3 cart is fully loaded and they give something to screw the upright support panels and lumber separators into.

 

 

 

 

 

 

 

 

 

 

 

After test fitting the pieces for the base frame, I drilled the holes for the pocket screws.

 

 

 

 

 

 

 

 

The base frame was then glued and screwed together.

 

 

 

 

 

 

To make the mounting blocks for the casters, I laminated 2 pieces of ¾” plywood together and the cut out the 4 triangular blocks and bolted the casters to them.

 

 

To attach the mounted casters to the base frame, I applied glue to the bottom corners of the frame, clamped them to the corners and screwed them down using piece of scrap to clamped sides to gauge the amount of overhang needed for the OSB.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Finally, I glued and screwed the top skin onto the cart base and the base was complete and very solid.

 

 

 

 

I hope you found this information helpful.

Next:  Building the Storage

Best regards,

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