Looking for a practical cart to make handling plywood and sheet goods easier? This project, created by Fanger Woodworking, is your solution. With a few materials and simple tools, you can build a Material Mate that enhances your workflow and makes transporting materials a breeze.
Materials Needed:
- 1×4 lumber (or 2×4 for added sturdiness)
- 3-inch casters (2 fixed and 2 swivel)
- Wood glue
- 1 5/8 inch screws
Tools Required:
- Miter saw
- Drill
- Jigsaw
- Clamps
Step 1: Build the Base
Start by constructing the base of the cart. The dimensions will be 36×22 inches. For this, you will need:
- Four pieces of 1×4 cut to 36 inches
- Three pieces of 1×4 cut to 20.5 inches
Glue the pieces together and secure them with clamps while pre-drilling holes for your screws. Use 1 5/8 inch screws to join the pieces. This will create a strong outer box. Don’t forget to add a middle brace for extra strength and ports on both sides for the wheels.
Step 2: Attach the Wheels
Once the base is assembled, it’s time to attach the wheels. This is straightforward—just screw them down into the designated ports you created earlier. The type of wheels you choose may vary based on your preference.
Step 3: Construct the Main Body
Now, let’s move on to the main body. Measure the height from the bottom plank (where the wheels are attached) and cut four pieces of 1×4 to be 3/4 inch shorter than that measurement. Two of these will attach to the back corners, and the other two will be placed in the middle.
Step 4: Add Vertical Supports
Next, add additional supports to the vertical pieces at both the top and bottom. This will enhance the stability of the main body. As you build, make sure everything is squared up using spacer blocks to align everything properly.
Step 5: Prepare for the Pivot Point
Using your homemade compass, draw a radius from the center point on the inside corner where the pivot point will be located. Drill out the pivot hole and then use a jigsaw to cut out the curve. This allows the top of the cart to rotate as needed.
Step 6: Create the Top
For the top, mark out a location for the pivot point, which will be 2 feet from the end. Drill a 5/8 inch hole for the pivot bolt, and check the fit to ensure everything aligns properly.
Step 7: Add Top Supports and Latch
Next, add more supports directly on top of the main body. This will help secure a latch that keeps the top in place when it’s fully opened. Make sure the latch has a solid joint to attach to.
Step 8: Install Swivel Stoppers
Finally, add the swivel stoppers—these are pieces of wood that will rotate up to prevent the plywood from sliding off when the top is folded down. Clamp them in place and drill quarter-inch holes to secure them with bolts and knobs.
