Kitchen Cart With Aluminum Legs

This cart was designed to accommodate a large garbage can. It measures 36 1/4" in height. The top shelf is 30 7/8" x 15 3/4" x 5/8".

Supplies

1. 3/4-in x 16-in x 6-ft Square Unfinished Spruce Pine Fir Board
2. 1-in W x 3-ft L Mill Finished Aluminum Square Tube
3. caster socks
4. casters
5. 3d printed parts: Brackets for Square Aluminum Tubes, M7 Screw adaptor
6. sandpaper (220, 320, and 600 grit)
7. varnish
8. masking tape
9. pencil
10. #6 1-3/4 in. Phillips Round Head Zinc Plated Wood Screw
11. #6 1/2″ wood screws
12. #6 1″ wood screws
13. Tools
14. hack saw
15. phillips screwdriver
16. drill
17. 5/32″ drill bit
18. hammer
19. wood chisel

20. scrap piece of wood

Step 1: Prepare Wood

1. Cut Pine Fir Board into two - 20 1/4" pieces and 1- 36 1/4" piece.* After the wood is cut, lay it flat until it is varnished.

2. Round the corners of the top layer by sanding it with a wood block covered with 220 grit sandpaper.

2. Lightly sand wood with 220 grit sandpaper.

3. Apply two coats of varnish to the top and one coat to the underside and edges. Use 220 grit sandpaper between top coats.

4. Finish top coat with 600 grit sandpaper.

*If you get the wood from Lowe's, it can be cut there.

Step 2: Prepare Aluminum Tubes

1. Cut 98mm off one end of each tube with a hacksaw.

If the tubes are scratched, etched, and dirty. Clean them with window cleaner, then sand with 320 grit sandpaper.

2. Place caster socket into uncut end of aluminum tube.
If the sock does not fit, first try sanding the inside of the tube with 220 grit sandpaper. If that does not work, trim the protruding sides of the sock with a chisel. Use a hammer to pound the sockets into the tube. Protect your floor with a scrap piece of wood while pounding.

Step 3: Attach Shelf Bracket to Tube

1. Place shelf brackets 3" from the bottom of the tube and 11 1/2" from top of the tube.

2. Secure position with masking tape.

3. Drill the tube using 5/32" drill bit. Drill again on opposite side. Repeat for each bracket.

Step 4: Attach Flange and Cover to Tube

1. Insert cut end of the tube into the flange.

2. Place masking tape on the tube to align with edge of the flange (on both sides of tube).Mark position 7mm from top of masking tape in center to align with hole (on both sides of tube).

3. Drill hole using 5/32" drill bit.

4. Put flange cover on tube. Tape flange cover to tube with masking tape, close to shelf bracket.

5. Attach the tube to the flange using 1/2" m6 screws. Repeat for each flange and tube.

Step 5: Attach Shelves and Top

1. Attach shelves to shelf brackets using #6 1-3/4" wood screws.

2. Position the tubes with attached flanges over the top shelf.

3. Screw the flanges to the top using 1/2" M6 screws.

Step 6: Insert Casters

1. Screw the flange covers onto the flanges.

2. Add the M7 adapter to the caster screw and insert it into the caster socket.

3. Turn the entire assembly over.

Finished.