Introduction: Scrap Cart From a Single Plywood Sheet (w/ Plans!)
In this project I am going to show you how to take a carefully designed cut list and a 4’ x 8’ sheet of 3/4” plywood and turn it into a really useful cart for scrap material. Check out the video below to see how, or continue into this intractable for a detailed write up with photos.
Step 1: PLANS:
I wanted to keep these plans as simple as possible, i recommend cutting the parts in alphabetical order, this will allow the kerf of your saw to undersize specific parts and will minimally effect the finished product. The rendering of the cart shows the locations of all the parts in the finished assembly.
To download a PDF of these plans check it out HERE:
Step 2: Break Down Your Material
My favorite way to break down sheet material is on the table with a track saw and rigid foam. While I do have a large table saw outfield table I still feel this way is the fastest and most efficient. I used 1 3/4” rigid foam used for insulation, and this allows me to make cuts freely with my blade running through the material and not worry about dulling the blade or damaging my table. Again, I am cutting the parts in alphabetical order as shown on the plans.
Step 3: Cut the Small Blocks
The small strip you will be left with can be cut up to make spacer blocks that you will use later for additional storage racks on the side of the unit. For this I recommend using a miter saw or hand saw since they are relatively small pieces.
Step 4: Assembly
To keep things simple I am using wood glue and 1 5/8” screws. I am not too crazy about making this perfect, but I want it to be strong. I recommend attaching the side panels to the back panel first.
From there I build up the inner dividers using the smaller dividing pieces as spacers to keep everything even.
Step 5: Resize the Middle Section Divider
The divider for the middle section will be left long based on the plans provided. I chose to cut mine using the miter saw, but this could easily be cut using a hand saw or jig saw.
Step 6: Continue With Assembly
With this mid section divider cut at the correct angle you can continue to screw and glue the parts together building the entire box up to the front panel.
Step 7: Attach the Bottom Panel
With the rest of the assembly complete the final part to be installed is the bottom. For this I chose to liberally apply glue to the ends of the dividers, and then flip up the bottom panel and screw it in. I made sure to use a good amount of screws on this section so it wouldn't come lose or bow under weight.
Step 8: Add Some Wheels
I really wanted my scrap bin to be mobile so I put some 150lb (each) rated casters on the bottom. These are attached with 3/4” wire lathe screws. Wire lathe screws are designed to hold wire mesh down and have a nice wide head that usually plays nice with the. large holes typically found in casters.
Step 9: Using the Rest of the Material
Technically the cart is complete, but I waned to try and use as much of the remaining pieces of plywood if possible. I decided to add some small sections to hold dowels and thin stock on the sides. To make these I used the small 1” wide pieces left over as standoffs and brought the wider pieces out to accept pieces tucked behind them. I put the lower bracket on the bottom, and the upper bracket about 2/3 up from that.
Step 10: Load It Up!!
Thats it! The bin is done and now its time to organize you space and fill it up. This bin stored a really large amount of material and I'm very happy with how it came out. If you have any questions let me know in the comments! Don't forget tot check out the video of this build in the first step, and if you like this project vote for it in the woodworking challenge here on instructables.
Runner Up in the