- 1 Plywood , (I recommend using ¾” thick plywood for the entire cart, but since I was using materials I had on hand, I used a combination of ¾” thick plywood and ¼” thick plywood.)
- 1 Project Panel , (optional)
- 1 Scraps , 1x2 scraps (optional)
Hardware & Supplies
- 1 Set of casters
- 1 Box of 1" wood screws
- 1 Box of 1/2" wood screws
Cut List & Parts
- 1 See instructions below
First, cut your wood to the following dimensions.
¾” thick plywood cut to 4 ft. long x 3 ft. high
Project panel cut to 4 ft long x 15 ½” wide
(2) Project panel pieces cut to 24” long x 15 ½” wide
(5) 1x2 scrap pieces cut to 3-4 inches long each
¼” thick plywood cut to 4 ft. long x 24” wide
(Alternate option: You could use ¾” thick plywood for the whole cart, but I was improvising and trying to use materials I had on hand.)
Drill Pocket Holes
Drill pocket holes along the longest side of your large ¾” thick plywood piece (spaced about 4-5 inches apart) as well as along each of the shorter sides, stopping about a third of the way up. Also drill pocket holes in one of the shorter sides and one of the longer sides of each of your side pieces.
Attach Back and Sides
Attach the bottom piece to the back using 1 ¼” pocket hole screws. Attach the side pieces to the back and bottom pieces, also using 1 ¼” pocket hole screws.
Add Scrap 1x2 pieces
This step is not needed if you use ¾” thick plywood for the whole cart, but since I was improvising I needed something to attach the ¼” thick plywood front piece to. I attached small 1x2 scraps (3-4 inches long) around the perimeter of the cart where the front would be attached, using 1” wood screws. I added a piece in each corner, one in the center at the bottom, and one where the top corners of the front would be. I made sure to leave a ¼” gap between the scrap pieces and the edge so the front piece would lay flush with the sides when attached.
I attached my front plywood piece to the scrap 1x2 pieces using 1” wood screws.
I attached casters to the bottom using ½” screws.