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Stair spindles make surprisingly good turned legs for a small cart — they're inexpensive, already shaped, and just need trimming to length and drilling for casters. Measure the square section at the base of each spindle carefully before cutting the leg notches into the bottom shelf; that square section is what registers the spindle's position and keeps all four legs sitting at matching angles.
Glue the caster wheels into the drilled leg bottoms rather than just press-fitting them — a cart pushed around by a kid takes real lateral stress on those wheel joints, more than the casters' own hardware alone is built to resist.
| Item | Qty |
|---|
| Pine, 1x12, 40 in | 1 each |
| Stair spindlesLegs. | 4 each |
| Plywood strips, 2-1/2" wide, 8 ftScalloped trim — 1x material or purchased trim works too. | 1 each |
| Dowel, 3/4"Handle. | 1 each |
| Pine, 1x3 and 1x2 scrapsHandle base and sides. | 1 each |
| Post-style caster wheels | 4 each |
| Wood glue | 4 oz |
| 2" wood screws | 1 box |
| Pocket hole screws, 1-1/4" | 1 box |
Overall cost: $$. Lumber prices vary by region, species, and season, so we give a band rather than a figure we would only be pretending to know.
| Part | Qty | T × W × L |
|---|---|---|
| Bottom shelfPine 1x12Notched to fit the square base of each spindle. | 1 | 3/4" × 11 1/4" × 20" |
| TopPine 1x12 | 1 | 3/4" × 11 1/4" × 20" |
| LegsStair spindle | 4 | 1 1/2" × 1 1/2" × 17 1/2" |
| Scalloped trimPlywood stripCut to fit around the cart's perimeter. | 1 | 1/4" × 2 1/2" × 96" |
Some parts are longer than a 8 ft board, so there is no honest board count to show here. Open the board plan to pick a longer stock length — it names every part that does not fit.
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Assumes 8 ft stock, a 1/8" saw kerf, and buying each part at its own width. Change the board size or kerf on the full board plan →
Measure the square base section of the stair spindles and cut a matching notch out of the bottom 1x12 with a jigsaw. Cut the spindles down to their finished leg length.
Attach the trimmed spindles to the bottom 1x12 with 3/4" pocket holes, 1-1/4" pocket hole screws, and wood glue applied to the underside.
Attach the top to the tops of the legs with 2" wood screws, predrilling every hole and using glue.
Drill holes in the bottom of each leg and insert the caster wheels, gluing them in place for extra hold against the lateral stress of daily use.
Build the handle from a 1x2 base and 1x3 sides, then attach the assembled handle unit to the top of the cart with 1-1/4" screws and wood glue.
Cut the plywood or trim strip to fit around the cart's perimeter, scallop the lower edge with a jigsaw, and attach with glue. Sand everything smooth and finish.
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