This project was built and designed by Chris from A Glimpse Inside. It’s a smart solution for managing plywood, lumber, and other large sheet goods in a crowded workshop.
Chris’s design not only offers solid storage but includes two hidden features that make it more functional than your average cart. If your shop is in need of organization and mobility, this is a project worth tackling.
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Why Build a Plywood Storage Cart?
Storing sheet goods flat and safely is a challenge in any woodworking space. Without the right setup, plywood tends to warp, clutter the floor, or get damaged while leaning against walls.
A mobile cart solves all of those issues by keeping materials secure and easy to access. Plus, being able to roll it around your workspace improves your workflow and saves time when handling heavy sheets.
Starting the Build
Chris begins with a sheet of Baltic birch plywood, known for its strength and stability. Two main sections are cut from the plywood—one for the base and one for building the A-frame support system.
Using a speed square and visual alignment, he cuts strips for the vertical and diagonal supports. These pieces form the structure of the A-frames, which serve as the backbone of the cart.
Building the A-Frames
Three A-frames are needed for the build—two identical and one mirrored to keep the overall look symmetrical. The mirrored piece ensures that both sides of the cart match visually while still offering functional support.
Once the pieces are cut, they’re joined together with countersunk screws. This method provides a clean appearance and adds durability without weakening the plywood.
Assembling the Base
With the A-frames ready, Chris flips the structure upside down to attach the base. This method makes it easier to align everything square and secure it properly.
The base is fastened using screws through the bottom, giving it the strength needed to support full sheets of plywood. Each connection is reinforced to help the cart withstand heavy loads over time.
Adding Casters for Mobility
Four heavy-duty casters are installed—two swivel and two fixed. This combination provides both stability and maneuverability, making the cart easy to move around the workshop.
Each caster includes a locking mechanism, which is essential for safety when loading or unloading large sheets. Once in place, the cart stays put until you’re ready to roll.
Hidden Functional Features
One of the standout elements in Chris’s design is a retractable support system. This extension can be pulled out to help stabilize long sheets while they’re being loaded or stored.
The second hidden feature is a French cleat storage system built into the back. This space is perfect for organizing long offcuts or narrow boards that usually don’t have a good home.
Final Touches and Loadout
With the cart fully assembled, Chris loads it with plywood sheets to show how it performs under real use. The angled design keeps the sheets upright and prevents bowing over time.
You can add your own custom touches, like finish or additional cleats, to suit your storage needs. The cart is built to handle years of use and makes workshop organization much easier.
Why You’ll Appreciate This Build
This plywood storage cart is a space-saver, time-saver, and all-around workshop upgrade. It’s easy to customize and makes managing sheet goods far more efficient.
By combining mobility, structure, and hidden features, Chris created a storage solution that fits the needs of real woodworkers. It’s a practical build that you’ll rely on every day.
Want to See the Full Build?
Please support Chris by visiting his website here: https://www.aglimpseinside.org