Miter Saw Cart

Submitted by Ana White on Wed, 04/11/2012 - 11:02
Difficulty
Beginner
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Make a miter saw cart from a single sheet of plywood! Has folding wings to stow away in tight spaces.

Hi everyone! Great news - we were able to set all the trusses last night! Thank you for all the well wishes, everything went well! I will share all the details with you in a Momplex post tomorrow.

Today I am pretty excited to share this new project plan with you!

Remember when Gina built this cedar shed to store her tools and work from?

Well, this gives her about 18 square feet to store all of her tools and work from.  We thought the best way to use this space for storing a mitersaw would be with a cart with extending leaves. 

So together we came up with this plan, and this is what Gina made.

We took extra measures to get it all in a single sheet of plywood to save us all money building.

Here's from Gina:

This was a super super quick build. I had the base built in under an hour, and got all the hardware attached the next day while dinner was cooking. I definitely included the use of pocket hole screws in the shelves for added stability, and really recommend that they're used consistently. The caster wheels I used are from Harbor Freight (I got 3 without breaks, and one with a break that is at the front right corner of the table) found here and here. They work fine. They're not bad, but you might have to swivel the cart for a sec to get it to go in the direction you want. No big deal.

The support hinges (mentioned in the shopping list) are amazing.

Thank you Gina!  Gina has also kindly put together a longer post with more details right here, so make sure you check it out for lots more tips and photos.



NOTE: The hinges used in this plan have not been tested for weight limits and are designed to be used to support boards being cut.  Use and build at your own risk.

Dimensions
Dimensions are shown above.

Preparation

Shopping List

1 – sheet 3/4" plywood cut in half lengthwise into 24” x 96” strips.
1 – 2x2 @ 8 feet long
1 – 1x3 @ 12 feet long – or 2 8 footers
4 – plate mount caster wheels with locking brakes
2 – shelf hinge supports http://www.woodcraft.com/product/2001690/3177/12-shelf-width.aspx

Cut List

2 – 3/4” plywood @ 24” x 36” (sides)
2 – 3/4” plywood @ 24” x 30” (shelves)
2 – 3/4" plywood @ 24” x 29 3/4" (leaves)
4 – 2x2 @ 24” (cleats)
4 – 1x3 @ 31 1/2" (supports)

Cutting Instructions

Cut plywood into two strips 24" wide x 8 feet long. From these strips, cut one each 36", 30" and then the remainder for leaves to get all cuts from a single sheet of plywood.

Tools
Tape Measure
Speed Square
Pencil
Safety Glasses
Hearing Protection
Drill
Circular Saw
Drill Bit Set
General Instructions

Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!

Instructions

Step 1

It is very important to place the cleat the distance down from the top of plywood edge equal to your saw deck height. Measure carefully.

Step 2

I'd also recommend attaching the shelves with 3/4" pocket holes and 1 1/4" pocket hole screws and glue, or brackets just to provide a little extra support.

NOTE: You can add extra shelves as well.

Step 3

These will reinforce the joint. Another idea is to add more lower down, like a crate, and you could use the bottom shelf for scrap wood storage. Note that the bottom trim is mounted flush to bottom.

Step 4

Mount your caster wheels to the bottom.

Step 5

Step 6

Finishing Instructions
Preparation Instructions
Fill all holes with wood filler and let dry. Apply additional coats of wood filler as needed. When wood filler is completely dry, sand the project in the direction of the wood grain with 120 grit sandpaper. Vacuum sanded project to remove sanding residue. Remove all sanding residue on work surfaces as well. Wipe project clean with damp cloth.

It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.

Comments

Gabe (not verified)

Wed, 04/11/2012 - 11:38

I think I would add two 2x2s under each wing running outwards where the hinge supports attach. Otherwise, with time, gravity is going to bow those wings downwards. The 2x2 fences will help this as well.

In reply to by Gabe (not verified)

Codding58

Wed, 06/15/2016 - 08:28

I agree with you, and am making the same modification on my build.  You can already see the sagging in the main picture on the ends of the wings compared to the material on the saw deck.   

A Crisp (not verified)

Thu, 04/12/2012 - 13:58

This makes me so unbelievably happy! I can't event tell you how much I need a set up like this. I will be rushing out to pick up up the necessities to make this come together. THANK YOU so much for another great idea!

redhead_61

Thu, 04/12/2012 - 16:46

I took a wood working class and he had all the tools in the shop set up so they were sunk into the nice long tables surrounding so that there were no problems cutting big 8 feet pieces of wood. This solves the need for small space building but WAY better cutting technique. AWESOME!