Must see homemade panel-cutting plywood cart!

In the video “Must see homemade panel-cutting plywood cart!” by Stumpy Nubs, James Hamilton shows us how to build a mobile plywood storage cart that doubles as a panel saw. This ingenious creation is constructed using common construction lumber and is designed to make breaking down full sheets of plywood a breeze.

Building the Structure

The cart is made from basic materials, primarily two by threes and two by fives, instead of the conventional two by fours and two by sixes. James starts by cutting these to length and ripping off the rounded edges, which gives a cleaner look and removes any rough mill surface. The assembly process is straightforward, using construction screws and simple butt joints, all done on the floor due to the cart’s size.

Cutting lumber for cart assembly

James meticulously constructs the base using 2 by 5s, ensuring that the distance between the inner rails will snugly fit the 2 by 3s for the next assembly. He installs robust six-inch casters to ensure mobility, though he notes a preference for locking casters for added stability in the future.

Installing casters on the cart

Assembling the Panels

The cart’s design includes tapered boards to avoid interference during cutting. James explains that while the taper isn’t crucial, it starts about an inch from the end and tapers to about an inch thick, allowing for seamless integration with the base assembly. He emphasizes that this isn’t a precision project, so minor discrepancies aren’t a big deal.

The next step is to mount the lower rail about five inches from the end of the boards on assembly two, which rests on the base. This strategic design allows the protruding ends to fit snugly between the rails set earlier. This assembly is further reinforced with additional screws wherever necessary.

Assembly of cart panels

Final Assembly and Usage

The final assembly divides the cart into two sections: one for full sheets and another for partial sheets. To determine the height of the small blocks that will support the plywood, James suggests marking the height of your wrist on the slanted side of the cart, then measuring 48 inches down. These blocks are crucial for supporting the plywood during cutting.

James demonstrates how to use the cart by placing a plywood sheet on the blocks and making a rip and a crosscut. He highlights the importance of using an edge guide and measuring the offset to ensure precise cuts. The cart’s design also allows for clamping to flatten bowed plywood, a common issue with inexpensive sheets.

Using the cart for cutting plywood

Conclusion

The cart is not only functional but also sturdy enough to hold a significant amount of plywood, as James shows by loading it up extensively. He encourages viewers to build their own version using the plans available in the video notes, proving that a simple circular saw can achieve tracksaw-quality cuts with the right setup.

Get the plans here.

Video

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