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A rolling plywood cart with fold-down leaves that support long boards level with the saw deck, plus lower shelves for storage.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Sides | 2 | 3/4" × 24" × 36" | Plywood | ☐ |
| Shelves | 2 | 3/4" × 24" × 30" | Plywood | ☐ |
| Fold-down leaves | 2 | 3/4" × 24" × 29 3/4" | Plywood | ☐ |
| Cleats Positioned to match your saw's deck height — measure before cutting. | 4 | 1 1/2" × 1 1/2" × 24" | Pine 2x2 | ☐ |
| Bottom trim supports | 4 | 3/4" × 2 1/2" × 31 1/2" | Pine 1x3 | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Plywood, 3/4", 4x8 sheet Ripped lengthwise into two 24" x 96" strips. | 1 each | ☐ |
| Pine, 2x2, 8 ft | 1 each | ☐ |
| Pine, 1x3, 12 ft Or 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 varies by region, species, and season, so we give a band rather than a figure.
Tools: Drill / Driver, Tape Measure. Materials: Plywood, 3/4", 4x8 sheet, Pine, 2x2, 8 ft
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.
Tools: Drill / Driver. Materials: Plywood, 3/4", 4x8 sheet, Wood glue
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.
Tools: Drill / Driver. Materials: Pine, 1x3, 12 ft
Add the bottom trim, mounted flush to the bottom, to reinforce the lower joint. A lower shelf can double as scrap wood storage.
Tools: Drill / Driver. Materials: Plate-mount caster wheels, with locking brakes
Mount the caster wheels to the bottom of the cart.
Tools: Drill / Driver, Tape Measure. Materials: Plywood, 3/4", 4x8 sheet, Shelf hinge supports, 12"
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.
Materials: Sandpaper, assorted grit
Sand every surface smooth and finish as desired.