Dust Collection Cart : 7 Steps (with Pictures)

Hello everyone, I'm Ashley and in this Instructable I'm sharing how to build a dust collection cart for the Ridgid shop vacuum and Dustopper (a cyclone dust separator for a 5 gallon bucket). This is a weekend DIY project that can be built from a single sheet of plywood.

Let's get started with the build!

The following are some of the tools and supplies I gathered to build my dust collection cart (affiliate links):

Track saw
Table saw
Pocket Hole Jig
Router with circle cutting jig or jigsaw
Drill / Driver
1 sheet of 3/4" plywood
1 1/4" pocket hole screws
3" caster wheels (4)
Screws and washers for caster wheel installation
wood glue

The 36″ hose that came with the Dustopper is a few inches too short so I used the hose that came with my Ridgid vacuum.

I also use a Bosch vacuum hose for my orbital sander. It’s a nice hose and I recommend it. It needs an adapter to connect to the Dustopper.

My dust collection cart is largely inspired by the dust carts built by John of John Builds It and Matt of MWA Woodworks. I merged my favorite features between the two carts into this one.

Step 1: Cut Parts According to Cut List

Break down the sheet of plywood into the following parts:

23 1/2″ x 40″ (Sides) x 2
24″ x 22″ (Base)
24″ x 14″ (Top Shelf)
4″ x 24″ (Braces) x 3
4″ x 22″ (Caster Supports) x 2

Step 2: Drill Pocket Holes

Grab a pocket hole jig drill and drill pockets holes on the following parts:

All four sides of the base
The short sides of the top shelf
The short sides of the braces

Step 3: Assemble the Cart

Assemble the cart following the diagram. Attach the two sides together via the top shelf and three braces. Install the base 3/4″ from the bottom of sides to allow clearance for the caster supports.

Step 4: Cut a Hole in the Top Shelf for the Bucket

Use a router with a circle cutting jig or a jigsaw to cut out a circle for the Dustopper bucket.

Step 5: Install Caster Wheels

Attach the parts for the caster supports to the base of the cart. Grabs screws and matching washers and install 4 casters to the underside of the dust cart.