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The single measurement that makes this cart actually useful is the cleat height: it has to sit exactly the distance down from the plywood's top edge that matches your own saw's deck height, so a board resting on the fold-out leaves sits flush with the saw table instead of tipping into it or sitting proud of it. Measure your specific saw before cutting anything — this number is not universal across brands or models.
The fold-down leaves are what let the cart double as a support table when the saw isn't in use, and also what let it collapse flat against a wall for storage. A second locking hinge support (beyond the plain shelf-hinge support) is worth adding if the leaves will also serve as an assembly table, since a single support isn't rated to hold a workpiece being pressed on or clamped.
| Item |
|---|
| Qty |
|---|
| Plywood, 3/4", 4x8 sheetRipped lengthwise into two 24" x 96" strips. | 1 each |
| Pine, 2x2, 8 ft | 1 each |
| Pine, 1x3, 12 ftOr two 8 ft boards. | 1 each |
| Plate-mount caster wheels, with locking brakes | 4 each |
| Shelf hinge supports, 12"A locking support is recommended if the leaves double as an assembly table. | 2 each |
| Pocket hole screws, 1-1/4" | 1 box |
| Wood glue | 3 oz |
| Sandpaper, assorted grit | 2 sheet |
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 |
|---|---|---|
| SidesPlywood | 2 | 3/4" × 24" × 36" |
| ShelvesPlywood | 2 | 3/4" × 24" × 30" |
| Fold-down leavesPlywood | 2 | 3/4" × 24" × 29 3/4" |
| CleatsPine 2x2Positioned to match your saw's deck height — measure before cutting. | 4 | 1 1/2" × 1 1/2" × 24" |
| Bottom trim supportsPine 1x3 | 4 | 3/4" × 2 1/2" × 31 1/2" |
Buy 7 boards at 8 ft.
2 boards
3 boards
2 boards
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 your own saw's deck height and mark this exact distance down from the top edge of the plywood sides — this is the single most important measurement in the build, since it determines whether a board resting on the leaves sits flush with your saw table. Attach the cleats at this height.
Attach the shelves to the sides. Pocket holes and 1-1/4" pocket hole screws and glue, or brackets, add a little extra support beyond resting on the cleats. Extra shelves can be added if desired.
Add the bottom trim, mounted flush to the bottom, to reinforce the lower joint. A lower shelf can double as scrap wood storage.
Mount the caster wheels to the bottom of the cart.
Attach the fold-down leaves to the sides of the cart with the shelf hinge supports, so each leaf folds flat against the cart when not needed and folds out level with the saw deck when in use.
Sand every surface and finish.
Sand every surface smooth and finish as desired.
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