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A three-shelf cart on casters from plywood and framing lumber. Roll it wherever the work is — garage, craft room, kitchen.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Shelf decks 1/4" or 1/2" thick per your load. | 3 | 1/2" × 15 3/4" × 48" | Plywood | ☐ |
| Shelf supports | 6 | 1 1/2" × 3 1/2" × 17 1/4" | 2x4 | ☐ |
| Legs | 4 | 1 1/2" × 3 1/2" × 33" | 2x4 | ☐ |
| Shelf ends | 6 | 3/4" × 2 1/2" × 15 3/4" | 1x3 | ☐ |
| Shelf sides Measure and cut to fit. | 6 | 3/4" × 2 1/2" × 49 1/2" | 1x3 | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Hardwood plywood, 4 ft x 4 ft 1/4" for light loads, 1/2" for heavy. Shelf decks. | 1 sheet | ☐ |
| 2x4, 8 ft (SPF / Pine) Legs and shelf supports. | 3 each | ☐ |
| 1x3, 6 ft (Pine) Shelf frame ends and sides. | 6 each | ☐ |
| Self-tapping screws, 2-1/2" Deck screws for exterior use. | 1 box | ☐ |
| Finish nails, 1-1/4" | 1 box | ☐ |
| Wood screws, 2" | 1 box | ☐ |
| Caster wheels, 2" diameter With mounting screws. Two locking casters are a nice upgrade. | 4 each | ☐ |
| Wood glue | 5 oz | ☐ |
| Stain or paint (optional) | 1 kit | ☐ |
Overall cost: $$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Circular Saw, Tape Measure. Materials: Hardwood plywood, 4 ft x 4 ft
Rip the plywood into three panels, each 15-3/4" wide x 48" long. Set a table-saw fence to 15-3/4" and run the sheet through, or measure, mark, and cut with a circular saw — or have the store make the cuts.
Tools: Drill / Driver, Speed Square. Materials: 2x4, 8 ft, Self-tapping screws, 2-1/2"
Assemble the two ladder-like leg frames from the 2x4 legs and shelf supports with 2-1/2" self-tapping screws (or pocket holes if you have a jig). Build them identical so the shelves land level.
Tools: Brad Nailer, Drill / Driver. Materials: Hardwood plywood, 4 ft x 4 ft, 1x3, 6 ft, Finish nails, 1-1/4", Wood screws, 2", Wood glue
Build the frame for each shelf first from the 1x3 ends and sides — nail and glue, use 2" screws, or pocket holes. Then apply glue to the bottom edges and nail the plywood deck onto each frame.
Tools: Drill / Driver. Materials: Wood screws, 2"
Set the shelves between the two leg frames at your chosen heights and screw them down, also screwing into the legs. Check the whole cart for square as you go.
Tools: Drill / Driver. Materials: Caster wheels, 2" diameter, Stain or paint (optional)
Attach the four casters to the base, making sure all four sit flat so the cart doesn't rock. Finish with stain or paint if you like — bare is fine for a shop cart.