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Versatile Shop cart/ workbench with inserts

February 26, 2013 |
posted by adecesare4
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Versatile Shop Cart with inserts for miter saw and kreg jig...or just a workbench top

Versatile Shop cart/ workbench with inserts

Handmade from this plan >>

Projects built from this plan. Thank you for submitting brag posts, it's appreciated by all!

About Project

Author Notes: 

Hello, today I drew up the plans for the shop cart that I posted a picture of the other day and by request...here come the plans :)

I have used this everyday since making it so I am so happy to share something that is useful with everyone...I hope you all enjoy!

Dimensions

Dimensions: 
32" high, , 25 1/2" deep, 37.5" wide

Materials and Tools

Shopping List: 

MDF or Plywood 3/4" - 2 sheets
Plywood - 1/4" 2' x 4'
3 1 x 3 x 8
4 1 x 4 x 8
1 1 x 2 x 8

1 1/4" kreg screws

Tools: 
measuring tape
pencil
safety glasses
drill
circular saw
compound miter saw

Cut List

Cut List: 

MDF or Plywood 3/4"
(2) 36 x 24
(1) 36 x 23 3/4

plywood 1/4 "
36 x 23 3/4

Pine
(4) 1 x 4 x 37.7
(4) 1 x 4 x 24
(8) 1 x 3 x 21
(2) 1 x 3 x 19
(2) 1 x 2 x 23 3/4

General Instructions

Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!

Step 1

Versatile Shop cart/ workbench with inserts

Create the base by using (2) 1 x 4 x 37.5" pieces and (2) 1 x 4 x 24" pieces

drill pocket holes on both ends of each 1 x 4 x 24" piece to attach to the end pieces...the 24" pieces go inside the 37.5:"ones

Step 2

Versatile Shop cart/ workbench with inserts

using the (8) 1 x 3 x 21" pieces, attach two together to form a leg...do this to make four legs

drill pocket hols to attach them and also pocket holes on each end to attach to the base and the top in the next step

Step 3

Versatile Shop cart/ workbench with inserts

Same as step one, just this goes on the top of the legs you just made

Step 4

Versatile Shop cart/ workbench with inserts

Insert the top MDF or Plywood 3/4 " piece. Inset this down 3/4 of an inch to leave room for all the inserts you can make

drill pocket holes all the way around the mdf or plywood piece to attach.

easy way for a little help is to attach two 1 x 2 pieces 1.5" down for support while you are putting the mdf sheet in place

Step 5

Versatile Shop cart/ workbench with inserts

insert a 36 x 24 mdf or plywood piece to the top edge of the bottom support

drill pocket holes all the way around and attach that way again.

Step 6

Versatile Shop cart/ workbench with inserts

attach the back 1/4" plywood piece using a brad nailer, small screws, or small nails

Step 7

Versatile Shop cart/ workbench with inserts

add side supports 1 x 3 x 19" on each side. measure 17 1/2 inches up from the bottom as your starting point

Step 8

Versatile Shop cart/ workbench with inserts

on the inside of those supports add a 1 x 2 x 23 3/4 piece.

this will be your shelf support

Step 9

Versatile Shop cart/ workbench with inserts

add the 36 x 23 3/4" mdf or plywood piece for the shelf...drill pocket holes on the sides of the mdf or plywood to attach it to the side supports

Step 10

Versatile Shop cart/ workbench with inserts

at the bottom add 2 1 x 3 x 24 piece for the casters to attach too...(the casters will attache in three spots without this piece, so it may not be necessary, but i like the added support

Step 11

Versatile Shop cart/ workbench with inserts

Here is the miter saw insert I made - LOVE THIS!!!!!!!!!!!

insert is 35 7/8" x 23 7/8"

i made the top pieces as high as my miter saw surface for extra board support

turns out those are nice and handy storage spots for smaller cut pieces to use later

Step 12

Versatile Shop cart/ workbench with inserts

Kreg jig insert I made

this insert is 12 x 35 7/8

i placed the jig in the middle on the top and made the pieces 1 inch high on each side (same height as board height on jig....nice for longer boards

i also placed handles on the outside top sides of this for easy carrying

Finishing Instructions

Preparation Instructions: 
Fill all holes with wood filler and let dry. Apply additional coats of wood filler as needed. When wood filler is completely dry, sand the project in the direction of the wood grain with 120 grit sandpaper. Vacuum sanded project to remove sanding residue. Remove all sanding residue on work surfaces as well. Wipe project clean with damp cloth. It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.

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Thanks for the plans

There as good Ana's plans. I will probably adapt the plans to build my own version of this shop cart, but I'll use 2x4s to strengthen it. And I'll add my own suggestion for a work top.
D.

posted by davidmauer14 | on Tue, 2013-02-26 17:53

Thanks David!

Sure...sounds like a perfect plan...it is very sturdy as but 2 x 4's will definitely do that...and your top idea was great as well...I did do that...just didnt take a pic of that....

David suggested also making a workbench insert that basically would use a 35 7/8" x 23 7/8 inch insert piece with another piece that would be slightly larger like 40 x 26 attached above it to make a nice solid workbench station as well. Great ideas, love collaboration

posted by adecesare4 | on Thu, 2013-02-28 00:35

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