This project was built and designed by Jason from PatriotDIY. It’s a space-saving plywood storage solution that swings out from the wall, helping you organize full sheets and scrap materials without cluttering your shop.
If you’re constantly battling piles of plywood offcuts or struggling to find what you need, this smart cart system might be exactly what your workspace needs. It combines simple construction with a clever swing-out feature that keeps materials accessible but out of the way.
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Solving the Scrap Wood Problem
Most woodworkers know the pain of a corner stacked high with warped offcuts and half-sheets of plywood. That mess not only eats up valuable floor space, but it also slows you down when you’re in the middle of a project.
Jason designed this swing-out cart to take control of that chaos. It stores full 4×8 plywood sheets vertically and keeps smaller scrap materials in check—all while allowing you to pivot the whole unit out from the wall when needed.
Prepping the Workshop Space
Before building the cart, Jason cleaned up the corner of his shop where it would be installed. This step isn’t just cosmetic—it helps you visualize the space better and ensures smooth installation later.
He also added paneling to the wall, giving him a solid surface to mount the swing-out hardware. That kind of prep work might feel like extra effort, but it pays off in the stability and longevity of the final result.
Building the Cart Structure
The cart is made in three key sections: a tall back section, a fully enclosed middle, and a shorter front compartment. Together, they create a stepped layout that allows different sizes of material to be stored in an organized fashion.
Jason starts by cutting the back section. He adds angled top corners for easier access—just a small design tweak that makes pulling out large sheets much more manageable. Once those pieces are assembled, he builds out the middle section using pocket holes and glue for strength.
The front section finishes off the structure, keeping the footprint compact while offering another area for smaller pieces. The result is a cart with built-in depth and function.
Reinforcing the Base
To ensure the structure can handle the weight of several plywood sheets, a second layer of plywood is added to the base. This reinforcement is key for stability, especially as the cart pivots in and out.
This layer also distributes the load more evenly, reducing wear on the casters and extending the life of the build. It’s a smart choice for anyone planning to load this thing up with heavy material.
Smart Caster Setup
Instead of installing four wheels as you might expect, Jason only uses three—two on one side and one on the swinging end. This layout keeps the cart from binding when you pull it away from the wall and helps control its motion during use.
It’s a great example of how less can sometimes be more when it comes to workshop mobility. The cart moves smoothly without tipping or shifting awkwardly.
Mounting and Hinges
Once the base and body are ready, Jason mounts the cart to the wall using heavy-duty hinges. These are secured into metal studs to ensure they can handle the full weight of the loaded cart.
He installs both top and bottom hinges for even support. After mounting, the cart is tested to swing freely without sagging or scraping against the wall.
Loading and Organizing the Cart
After installation, it’s time to load the cart. Full sheets of 4×8 plywood can stand upright in the back compartment, while shorter sheets and scraps fit neatly into the front and middle sections.
There’s even room behind the cart to slide in a few extra sheets or long strips of offcut material. This design keeps everything upright, easy to sort, and simple to access.
Adding Vertical Scrap Storage
To complement the plywood cart, Jason also installs a vertical rack for storing leftover dimensional lumber and trim pieces. Mounted to the wall, this rack holds narrow boards upright, keeping them off the floor and out of the way.
Together, these two systems create a complete shop storage solution. Plywood, scraps, and offcuts each have a designated spot, transforming a cluttered workshop corner into a clean and efficient work zone.
A Workshop Upgrade That Makes a Difference
The swing-out plywood cart is more than just a clever build—it’s a practical improvement that pays off every time you reach for material. It frees up floor space, makes it easier to find what you need, and brings order to one of the most frustrating parts of any shop.
Jason keeps the build approachable with common tools, clear layout, and no unnecessary complexity. Whether you’re running a full shop or working out of a garage, this is a project that can improve your workflow right away.
Please support Jason by visiting his Etsy Store: https://www.etsy.com/shop/patriotdiy.