I decided to build a set of shop carts from the scraps of various projects. The carts are very handy, as they can be easily pushed out of the way to make room to work on large pieces.
This is the first cart in the series.
I made it at Techshop: http://www.techshop.ws
Step 1: Materials and Tools
(The exact amount of plywood will vary based on your cart size)
3/4 plywood - for the tray sides and legs I cut this from scrap, but you should be able to cut all from a 1/2 sheet.
1/2 plywood - two rectangular sheets for the cart trays-typical sizes are 18x24 and 24x36 -less than 1/2 sheet
1 inch coarse pocket screws - 12
3 inch fixed caster wheels - 2
3 inch swivel caster wheels -2
mounting screws and washers for the casters- 16
Any plywood friendly 1/4 router bit- this is a shop cart - not worried about tearout on the cut..
Pocket screw jig and driver
Step 2: Design
I researched dimensions for shop carts on the web with 3 inch wheels and used this for my starting point. The typical tray sizes were 18x24 and 24x36 inch.
I wanted to make a very strong cart that was supported and locked in place by the plywood itself, and not reliant on fasteners that could loosen over time. This required a generous amount of large interlocking cutouts, tabs, and full mortice and tenon joints.
I ddi not want any handles on the carts, so that multiple carts could be packed tightly together is a small shop.