Introduction: DIY Mobile Plywood and Lumber Storage Cart | Only 1 Sheet of Plywood!

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About: I am a self taught maker that has fallen in love with making instead of buying. I create how-to videos about the projects I love and make. Check out my YouTube channel for more!

For far too long my garage workshop has had an unorganized pile of plywood and wood scraps taking up lots of space along one wall. So I finally tackled this problem and built a Mobile Plywood/Scrap wood storage cart to organize this space and also get the wood up off of the ground. 

Aside from the 2x4 base, I built this whole cart out of one sheet of plywood! I also love that it is mobile, doesn’t take up much space and the organizational dowels are so helpful.

Supplies

Things I used in this project:

One 3/4 Sheet of Plywood

2 2x4's

Circular Saw: https://amzn.to/2WSrF7Q

Track Saw: https://amzn.to/3g9JMRS

Drill: https://amzn.to/2ULFuYm

Driver: https://amzn.to/2MJGYgp

Jigsaw: https://amzn.to/2TWrxbH

Pocket Hole Jig: https://amzn.to/2QzkoZh

Forstner Bits: https://amzn.to/39womuH

Bessey Trigger Clamps: https://amzn.to/3kyFaqL

Counter Sink Bit: https://amzn.to/2sASfJd

Casters: https://amzn.to/3vhtfma

Dowels: https://homedepot.sjv.io/2r5Em0

Glue: https://amzn.to/2D8lqFx


My friend Pink Soul Studios collaborated with me and created plans for this build with all of the dimensions and a cut list here: https://bit.ly/2YXG60C

Step 1: PreCut All the Parts

I’m going to be building this project out of one, 4x8 sheet of plywood. 

I used my track saw and table saw to break down the sheet into parts, but you can just as effectively use a circular saw and a straight edge. 

The base of this cart is made out of 2x4’s, which I easily cut to size with my circular saw.  

Step 2: Cut the Handles

Since this cart is mobile, it's helpful to have handles.

To do this, I traced two circles on the support pieces and then cut them out with a forstner bit. Then I drew lines to connect the two circles and cut out the center with a jigsaw.

And now I have a super simple handle! 

I used my first handle as a template to trace the handle cut on to the other two boards and cut them out to easily cut two more. 

Step 3: Cut the Pockets Holes

Before assembly, I need to cut out the pocket holes, which is how I’m joining all of these boards together. I set up my pocket hole jig and then went through each board, adding the pocket holes where necessary. 

Step 4: Cut the Holes for the Grid of Dowels

I’m going to add large dowels to one side of this cart, which will help organize the scrap wood. Cutting the holes for them now will be easier than when it’s assembled. 

I lined out a grid where my holes will go and I’m again using a forstner bit to cut out these holes, which gives a clean cut.

Step 5: Assemble the Base

Ok, let's assemble the base. I brought out my cut 2x4’s and laid them out.

I then added glue to make the connections super strong and pushed everything into place. I've got two long sides and 5 short center support boards. I then screwed everything together.

Keeping these boards in place while I screw everything together is much easier with clamps and these trigger clamps made assembly, throughout this build, so much easier. 

The top of the base will be covered with plywood. I placed the plywood board on the top. And then to attach it, i used screws straight down from the top. I took the time to pre-drill with a counter sink bit, which carves out an area in the wood, letting the screw head sit slightly below the surface. This way nothing will snag on these screws in the future. 

Step 6: Add the Casters

I want this cart to be mobile so I’m attaching heavy duty casters to the bottom. I made sure to buy casters with locking wheels so it stays in place when I don't want it to move. 

Step 7: Attach the Plywood Top

I placed the large plywood top vertically on top of the base and clamped trigger clamps to both ends. This is a great trick to temporarily become braces and hold a vertical piece in place. And then I screwed it all down with pocket holes.  

Step 8: Attach the 3 Support Pieces

The support pieces are going to have horizontal dowels connecting them, which means I need a few more holes drilled to accept the dowels. 

Once the holes were drilled, I added glue for extra strength and then screwed the left end support part into place using pocket holes.

Before I can add the center support, I need to insert the horizontal dowels. I added a little glue to keep them secure and then I twisted them into the holes and into place. 

And now we’re ready for the center support. I added glue, set it in place, hammered it snug onto the dowels and then added screws. And then repeated for this third support. 

Step 9: Insert the Grid of Dowels

And then finally, I could cut the 9 short dowels to create the outward facing grid dividers on right hand side, attaching them with glue. These dowels are going to be great dividers, helping to add organization to this cart. 

Step 10: Last Step! Attach the 3 Side Walls

The last thing to do was to add these three short wall boards, which includes these front two horizontal pieces, which I glued and screwed into place with pocket holes from the back. And then this long board on the back, which will help to hold the plywood sheets in place. 

And with that, this plywood storage cart was done!

Step 11: All Done!

Seeing the wood pile get reorganized back onto this cart is my favorite part. I’m excited to have something for my plywood storage needs and storage for the smaller scraps that I have. And I love that the whole body of this cart was built from only one sheet of plywood.   

Also! This cart can also be modified to fit your needs. My friend Pink Soul Studios built one that utilizes one side as clamp storage.

Don't forget to watch the full build video above to see a more detailed tutorial.

I'd love to see pics of yours if you decide to make your own! For more projects and tutorials, be sure and visit my YouTube channel and my website. You can also find me on Instagram @makergray.  

Thanks!