This project was built and designed by Jay Bates. It’s a compact, mobile cart that combines a shop vacuum and a cyclone dust separator into one efficient unit—perfect for small workshops where space and mobility are key.
The build focuses on reducing clutter, improving dust collection, and keeping hoses and accessories organized in one place. It’s a thoughtful solution for anyone tired of dragging separate tools around the shop.
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Why a Cart Like This Makes Sense
Jay’s motivation for this project came from two common workshop frustrations: mobility and mess. Using a vacuum and a cyclone together is a smart setup, but moving them separately across the shop floor is inconvenient and inefficient.
Hoses tend to pile up, accessories get misplaced, and valuable floor space disappears. A compact, upright cart that holds both systems in one place is a smart upgrade for any woodshop.
Planning the Layout
The cart is designed with a vertical stacking approach. The shop vac sits on top, while the cyclone separator is positioned underneath, supported by a sturdy frame.
This layout keeps the footprint small and mimics the feel of a hand truck or dolly, making the cart easy to maneuver. The design also leaves room for hose storage and tool attachments, so everything needed for dust collection is right where it should be.
Materials and Tools
Jay uses plywood to build the cart’s structure, selecting a thickness that’s sturdy enough to hold both machines without making the cart too bulky. A variety of screws, glue, and pocket hole joinery techniques come into play during assembly.
The original casters from the cyclone separator are reused, helping keep costs down. Larger wheels could also be added if the cart needs to roll over uneven ground or move between workshop and garage.
Building a Strong Base
Construction starts with the base platform that supports the cyclone. Jay adds a lip around the perimeter to keep the cyclone locked in place during movement. This detail helps prevent tipping and adds to the overall stability of the unit.
From there, upright supports are added to elevate the shop vacuum above the cyclone. These supports are spaced and braced to ensure the top unit is balanced without putting pressure on the bottom one.
Comfortable Handle Design
The cart includes integrated handles that allow it to tilt back and roll like a dolly. Jay takes time to shape the handles for comfort, making sure they’re easy to grip and placed at a natural height for pushing and pulling.
Clearance is also considered—both between the units and at the base—to make sure nothing catches or blocks access to key components. Every design choice supports ease of use in a working environment.
Storage and Hose Management
On the back side of the cart, Jay adds hooks and compartments to organize hoses and attachments. This ensures everything has a dedicated spot and keeps cords, tubes, and tools from cluttering the floor.
By having the entire dust collection setup in one rolling station, cleanup becomes faster and setup for each task more convenient. It’s one of those improvements that pays off every time the tools are used.
Adjustments During the Build
As the cart comes together, Jay realizes the exhaust hose between the cyclone and vacuum is a bit short. This isn’t a major issue—just a reminder that even simple builds may require mid-project tweaks.
The cart’s dimensions are flexible and can be adjusted depending on the exact models being used. Whether you’re working with a small shop vac or a larger commercial unit, the general plan can be adapted to fit your gear.
Final Testing and Finish
Once assembled, Jay tests the mobility and weight balance of the cart. It tilts easily, rolls smoothly, and keeps both the vacuum and cyclone steady, even when moved across the shop floor.
He adds a finish to protect the wood and make cleanup easier. Whether you go with a clear coat or a coat of paint, finishing the cart helps it stand up to daily use and exposure to sawdust and moisture.
Sharing the Results
Jay makes the plans for this cart available on his website for anyone who wants to follow along or customize their own version. He encourages others to post their builds online, offering a great way for the woodworking community to share ideas and improvements.
As always, Jay continues to post new projects and helpful videos on his channel each week. If you’re looking for smart shop upgrades or creative builds, his channel is a great place to stay inspired.
Please support Jay by purchasing his plans here: Jay’s Custom Creations.