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.

miter saw cart
miter saw cart
miter saw cart
miter saw cart
miter saw cart
miter saw cart

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
miter saw cart
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 NOTE: For use as an assembly table we recommend a locking support as well
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.
Help Improve This Plan

We apologize if there was an error in this plan. Please help us out and report any errors here.

Comments

Milca (not verified)

Mon, 04/16/2012 - 17:29

And was trying to figure out how to maximize my space (10x12 approx) room in basement for those long winter months. This will be great! I can have it set up by the wall, think workbench, but still be able to easily move the saw forwards when cutting longer lumber [so it can stick out the doorway]. Anyways... makes sense in my head :) Thanks Ana. LOOOOVE your site! Milca

hiswif26 (not verified)

Tue, 04/17/2012 - 13:23

OMG Thank you so much for posting this. My husband and I were looking at buying a miter saw last weekend, but didn't have anything to put it on so decided to hold off. This will be perfect!!

Linda7

Thu, 04/19/2012 - 19:48

I am so excited to begin building this cart! Great job on the plans, Ana, and wonderful build, Gina. I do have a question regarding the placement of the shelf for the saw. If I place the cleat exactly the same distance from the top of the plywood as the height of the deck, and then attach the shelf to the cleats, won't that raise the deck 3/4" above the height of the wings? OR does this have something to do with the placement of the folding shelf brackets? I am not good at figuring this stuff out, so would appreciate your explanation. Thank you.

Michael B (not verified)

Fri, 04/20/2012 - 14:40

Hi, great job with this. Planning on building this for my shop now. Do you know if the shelf hinges come in pairs? Is that why you put two for the quantity needed?

RNorman (not verified)

Mon, 04/23/2012 - 07:00

They do come in pairs. The same supplier is also having a special on casters, FYI if you choose to get it all from one source.

Hellgamatic (not verified)

Tue, 04/24/2012 - 15:05

Does anyone know of a way to reduce the price of building this? The hinges are $32 for the set of four, and my budget is like $30 total :/ Is there some other way to make the shelf supports? Regular hinges and some kind of wood brace, maybe? I really really want this to be my first *real* project because it is a step towards all of my other projects going smoothly...

crouton976 (not verified)

Sun, 05/13/2012 - 00:13

Well, you could possibly make some stops out of 2x2 that run from the front of the wings to the back, then hinge another piece made out of 2x4 with both ends mitered that you manually raise to brace the wings... One side against the wall of the base, the other against the side of the stop.

Let me know if you need a sketch...

In reply to by Hellgamatic (not verified)

Lady Goats

Wed, 05/16/2012 - 13:23

Scroll sown to "build the flip-up assembly table" on this site http://www.familyhandyman.com/DIY-Projects/Woodworking/Workbenches/modu… - gives a cheap way of accomplishing the flip-up aspect. It's a little inconvenient having to store/find the boards to hold the leaves up, but if you can manage, it'll save the $$ of the hinges!