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

frankb03

Wed, 03/23/2016 - 13:06

I bought a pair of Chrome Steel Folding Shelf Bench Table Folding Shelf Bracket 330lbs for $18

claydowling

Wed, 05/16/2012 - 19:39

This is a prime opportunity to pull out some tricks from the world of drop leaf tables. My personal favorite, for ease of construction, is a pair of sliding bars under the leaves that slip into the table when they aren't needed.

The other cool trick was used by somebody here to put leaves on the farmhouse table. There were bars attached to the underside of the leaf that slid into sockets in the table.

Lady Goats

Tue, 05/22/2012 - 20:45

Hi everyone! A few days ago, one of the leaves fell off of my miter saw cart as I was lifting it to do a project. It just pulled right off of the screws, and landed uncomfortably close to the big kid, who was painting some scrap wood nearby. Freaked. Me. Out!

My initial thought was that the leaf was too heavy for the screws that came with the hinges (they state that they can hold up to "x" amt of weight, but that's when they're upright... It didn't say anything about how much weight the poor little screws can hold when it's dropped down!). So I took a smaller ply scrap that I had and screwed it on. It wasn't very pretty, but it was workin' so far....

Fortunately for me, a friend was asking about the leaf size the next day (what're the odds? She had the leaf cut a little too short and wondered if that'd be ok!), and I told her what happened. She then went and asked around for advice, and it seemed like all of the suggestions were to add another support that folds out under the leaf when it's lifted (which just didn't seem to make sense to me.. the hinges hold the weight, and that doesn't affect the screws)... Blah blah blah, back to the story!

The screws pulled out of the leaf, but were still strong on the cart itself, so I put 3/4" anchors (the kind that you use in drywall - but the ones I have I got from walmart and they said they work in drywall, stucco and wood, so I'd just look for ones that work for wood) into the holes in the leaf, and screwed the leaf back onto the hinge.

I spent about an hour lifting and dropping the leaf (making sure to engage/disengage the hinge each time), and have been using my saw regularly in the past couple days, and I'm not seeing any sign of the screws loosening. I'll definitely keep you posted if there's a change!

moonhopping

Sat, 08/31/2013 - 22:54

Thanks for the update. It is finally below 90 degrees so excited to be able to get building. I am going to start on this tomorrow and will pick up some anchors before I start. Thank you for sharing your amazing plans.

CanadaMarg (not verified)

Sat, 09/29/2012 - 20:34

Thanks for the plans and these comments! I made the cart this afternoon out of an old Ikea cabinet that was junk from a friend's kitchen reno, and some building material scraps. I had to make the wing "locks" out of 2x2's bc i live out in the country and didnt want to make a special drive past out nuts-and-bolts hardware store. Total investment- $15!
The best part- now I can roll the mitre saw outside when I do projects, and keep the garage from getting so dusty!

coasterbrake

Thu, 04/04/2013 - 09:14

It was super-easy to build this. My tips are:
-- buy locking caster wheels. That really should have been obvious, but wasn't to me.
-- don't forget to acquire fasteners for the support pieces. I used nails left over from previous projects
-- do only one folding shelf if you need to reduce costs (or if you forgot to buy two PAIRS of brackets)
-- a long clamp will serve you well when you're screwing it together. Otherwise, you may need another set of hands to get everything square.

davidmauer15

Thu, 07/11/2013 - 13:43

I can see three ways of propping up the wings.
1. Use the metal shelf supports that Gina suggests. Expensive though.
2. Some people have put in two stop blocks and put a 2x2 or 1x2 in to hold up the wings. I tried this and it works okay, especially if you use two pieces of wood per side.
3. Couldn't you make some sort of hinged support that folds out to hold up the wing and then folds away when you don't needs the wings?

G5Flyr

Thu, 05/22/2014 - 20:26

Thanks for coming up with this and posting it for all of us. This is by far the simplest and least expensive of any DIY miter saw station I have seen. I can't wait to get started!