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A rolling shop cart with a recessed top that swaps interchangeable inserts — a flat bench today, a miter-saw station or Kreg-jig station tomorrow.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Top and base panels | 2 | 3/4" × 24" × 36" | 3/4" plywood/MDF | ☐ |
| Shelf panel | 1 | 3/4" × 23 3/4" × 36" | 3/4" plywood/MDF | ☐ |
| Back | 1 | 1/4" × 23" × 36" | 1/4" plywood | ☐ |
| Base/top frame long | 4 | 3/4" × 3 1/2" × 37 1/2" | 1x4 | ☐ |
| Base/top frame short | 4 | 3/4" × 3 1/2" × 24" | 1x4 | ☐ |
| Leg halves Two laminated per leg. | 8 | 3/4" × 2 1/2" × 21" | 1x3 | ☐ |
| Side shelf supports | 2 | 3/4" × 2 1/2" × 19" | 1x3 | ☐ |
| Shelf ledger supports | 2 | 3/4" × 1 1/2" × 23 3/4" | 1x2 | ☐ |
| Caster mount boards Added at the bottom to give the casters solid backing. | 2 | 3/4" × 2 1/2" × 24" | 1x3 | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| 3/4" MDF or plywood, 4x8 sheet Top, base panel, and inserts. | 2 each | ☐ |
| 1/4" plywood, 2x4 ft Back. | 1 each | ☐ |
| 1x3 board, 8 ft (Pine) Legs and supports. | 3 each | ☐ |
| 1x4 board, 8 ft (Pine) Base and top frames. | 4 each | ☐ |
| 1x2 board, 8 ft (Pine) Shelf supports. | 1 each | ☐ |
| Pocket-hole screws, 1-1/4" | 80 each | ☐ |
| Locking casters, 3" All four corners, at least two locking. | 4 each | ☐ |
| Wood glue | 6 oz | ☐ |
Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Drill / Driver, Pocket Hole Jig. Materials: 1x4 board, 8 ft, Pocket-hole screws, 1-1/4"
Make the base from two 1x4 @ 37.5" and two 1x4 @ 24" pieces, the 24" pieces set inside the long ones. Pocket-hole both ends of the short pieces to join them. This is the bottom of the cart.
Tools: Drill / Driver, Pocket Hole Jig. Materials: 1x3 board, 8 ft, Pocket-hole screws, 1-1/4", Wood glue
Glue and pocket-screw two 1x3s together to form each L-shaped leg, four total, with pocket holes at each end to attach to the base and top. Fasten the legs to the base frame.
Tools: Drill / Driver, Pocket Hole Jig. Materials: 1x4 board, 8 ft, Pocket-hole screws, 1-1/4"
Build a second 1x4 frame identical to the base and fasten it to the tops of the legs. The cart's box is now standing.
Tools: Drill / Driver, Pocket Hole Jig. Materials: 3/4" MDF or plywood, 4x8 sheet, Pocket-hole screws, 1-1/4"
Drop the 3/4" top panel into the top frame inset exactly 3/4" down, so a 3/4" insert will land flush. Clamp a pair of 1x2s 1-1/2" down inside the frame as a ledge to rest the panel on while you pocket-screw it all the way around — holding it at an exact reveal one-handed is a losing fight.
Tools: Brad Nailer, Drill / Driver, Pocket Hole Jig.
Nail or screw the 1/4" back on. Add the 1x3 side supports 17-1/2" up from the bottom, then a 1x2 shelf support inside each, and drop in the shelf panel, pocket-screwing its sides to the supports. Add the caster mount boards at the bottom and screw locking casters to all four corners.
Tools: Circular Saw, Drill / Driver, Miter Saw. Materials: 3/4" MDF or plywood, 4x8 sheet, 1x3 board, 8 ft, Pocket-hole screws, 1-1/4"
Cut flush inserts at about 35-7/8" x 23-7/8" to sit in the recess. For a miter-saw insert, build up side wings to the saw's bed height so long boards ride level — those wings double as storage for offcuts. For a Kreg-jig insert, mount the jig centered with 1"-high side rails at the jig's board height, and add handles for carrying. Store the spares on the lower shelf.