- 4 Boards , 1x4
- 1 Project Panel , 16” W x 4’ L
- 3 Boards , 2x2
Hardware & Supplies
- 4 Casters
- 1 Box of ½” Screws
- 1 Box of 1 ¼” Pocket Hole Screws (See tools list)
- 1 Box of 2 ½” Pocket Hole Screws (See tools list)
- 1 Box of 2" Wood Screws
- 1 Paint or Stain
Cut List & Parts
- 4 Frame , 1x4 cut to 16” long
- 4 Frame , 1x4 cut to 25.5” long
- 4 Legs , 2x2 cut to 32” long
- 4 U-Shape at top of legs , 2x2 cut to 12 ½” long
- 2 Shelf Bottom , Project panel pieces cut to 24” long
Cut your wood to the cut list dimensions.
Use a random orbit sander to sand everything smooth.
Drill Pocket Holes
I used the Kreg Jig 520PRO to drill pocket holes as follows:
-1 pocket hole at each end of both 12 ½” long 2x2 pieces
-2 pocket holes at each end of (4) 15” long 1x4 pieces
-Pocket holes around the perimeter of each project panel (I drilled 4 on each side and 3 on each end)
This utility cart has two shelves, so in order to build those I attached the shorter 1x4 pieces to the longer 1x4 pieces, forming two separate frames using 1 ¼” pocket hole screws.
Next, I attached each frame to a project panel (this forms the bottom of the box/shelf) using 1 ¼” pocket hole screws.
For the legs, I attached each of the short 2x2 pieces to two of the longer 2x2 pieces (perpendicular), forming a “U” shape. I repeated this process so I had two “U” shaped pairs of legs.
Attach the Legs
Now it’s time to assemble! I measured 5” down from the handle (the “U” shape part of the 2x2 pieces we assembled is the handle), and working with the cart on its side I placed my first shelf there. I attached it by drilling (2) 2” wood screws from the inside of the shelf into each of the 2x2 legs.
For the second shelf, I used a ruler as a spacer and placed the shelf 12” below the first one, attaching it the same way (2 - 2” wood screws into each leg).
Stain or Paint
I finished the cart using a Provincial wood stain. You can use the topcoat of your choice as well.
The final step is to add casters after your paint or stain has dried. I flipped the cart on its side and attached small casters. I couldn’t find any small enough so I improvised by just screwing into one side of the bracket since the bracket is a little too large for the 2x2. They still work just fine! I attached them using ½” long screws.