Pizza delivery cart made from wood and industrial-strength metal casters. It was made mostly from wood that was being discarded, so I will try to describe the build with as much detail as possible.
Some of the basic parts are:
1. 4 industrial-strength steel casters from Home Depot
2. T20 screws, 2 inches long. 3. Various types of 1.5 inch screws, both Phillips and Torx
4. 2x3 and 2x4 pieces of Pine wood, each about 2 feet long
4. 2 wood shelves, 1 foot x 2 feet (pretty sure it is Pine, but not 100% positive)
5. 1/2 inch plywood, 2 feet x 3 feet
6. Small pieces of wood of various sizes
7. Metal mending plates

Step 1: Build Out Platform

1. Using a double-glue joint, glue the 2 wood shelves together.
2. Take a 2 foot piece of 2x3 and 2 foot piece of 2x4, and attach them to the platform using the T20 screws. When attaching them, screw them *across* the glue joint to reinforce it.
2. Screw down discarded wood pieces and mending plates across the glue joint to further reinforce the glue joint. Here I used screws that were 1.5 inches long, Phillips and Torx.

Step 2: Screw Down Steel Casters

1. Screw down 4 steel casters into the 2x3 and 2x4 on each corner of the platform using the 2 inch T20 screws.
2. In addition to the screws in the 4 caster holes, I screwed in about 25 of the T20 screws around the edges of the caster base at about a 45 degree angle. I put in a large number of screws since the wheels were going to be experiencing a tremendous amount of vibration while being used on sidewalks in the Financial District in Manhattan. The side screws will help anchor the caster better from the vibrations it experiences.
3. The basic platform is now complete and ready to attach the handle.

Step 3: Attach Vertical Supports and Hoizontal Handle

1. Using about 20 of the T20 screws, attach 2 of the 2x3s vertically to the platform. I used about 10 screws on each vertical support. I used a large number of screws since this butt joint was going to have a lot of stress put on it and I could not put in additional wood support brackets since the platform needed to be open so it could be loaded up with pizza and soda.
2. Once both vertical supports are secure, take a 3rd piece of 2x3 Pine and attach them together horizontally to form a handle. I used about 4 of the T20 screws to secure it to each vertical support (8 total).

Step 4: Secure 2 Foot X 3 Foot Plywood

1. Once again, using the T20 screws, secure the 2 foot x 3 foot plywood board to the main platform. The owner required a bit more length for the delivery cart, so the plywood would provide that. I used about 18 screws.
2. The T20 screws were a bit long for attaching the plywood, so they stuck out at the bottom. I made notes on the platform warning the delivery guys about this and also noted where it was safe to grab the platform if they needed to.
3. The next version will be made of store-bought materials and custom designed from the ground up for the needs of the pizzaria.. This version will be used as a test version to get feedback from the workers and owners.

If you do a rebuild I would suggest adhesive along with the screws (about 10 times less screws) or metal brackets at the joints that are fairly cheap at any hardware store.
Good points. With regards to the adhesive, I did not have the time. I had to build the platform in my apartment, bring it down to the pizzaria and the 2x3s on the subway, then assemble it at the pizzaria within a few hours. The metal brackets would be good, particularly a 90 degree one on the platform. The owners wanted a completely clean and smooth platform, so I had to forgo using them. But perhaps on Version 2!
I think you'd be wise and a lot more screws to that thing. It doesn't look like you have enough to handle more than a few pizzas without risking the whole thing breaking apart.<br><br>Better safe than sorry ?
When we were testing it, we in fact had some concerns about the 2 butt joints that are attaching the vertical supports to the platform. I put in about 10 to 12 T20 screws into each 2x3, and we were still getting a bit of flex in the joint. We did a quick test with a case of bottles water and it seemed to hold. But you are right, the real test will come when they load it up with 10 pizza pies and a case of soda, which would be pushing about 120 lbs. If it fails we will do a redesign from the ground up.

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