Assembly Cart concept, design, and build #2: The Design and Intial Build

  • Advertise with us
Blog entry by RandyMarine posted 10-30-2010 08:15 PM 1595 reads 1 time favorited 2 comments Add to Favorites Watch
« Part 1: Part #1 The Concept Part 2 of Assembly Cart concept, design, and build series no next part

Greetings All,

Well, as I said in the first part…I grabbed out my original sketches and they looked nothing like what I had in my mind now, but knew I wanted to incorporate some of my original ideas into the final design. So, I grabbed my DRY ERASE MARKER…and made a cardinal mistake. I rough sketched my final design (going completely crazy on details) on my large whiteboard. I Would have been fine, until my g/f erased the whiteboards a week later, not knowing I hadn’t completed the transfer to paper! My office area is in the master bedroom and well….I will just post a ton of pics instead..:)

Being completely frustrated I went straight to the shop with the mental image. But here are the 3 Projects…
the originator (for me anyway)..
Click for details

Then the Original originator..
Click for details

And Finally the Glue..
Click for details

Thank you to JimNEB for providing me with his plans. Like I said in the first part, it was very informational and answered a large number of my newbie questions. ( I got to save some dignity). Unfortunately, I am still trying to figure out how to share them on my blog…hoping to have that done by part 3.

Being that I had never built anything like this, but a book case…I had to really use my brain to come up with my own dimensions. I grabbed my clamps and laid them on the bench and started tracing and measuring a template..

As you can see, I didn’t like my first attempt (right side of the 2×4). I did get it right on the second time around…with this layout template I got my cart width of 37”. I did the same with my Cabinet Master clamps, and got a total cart depth of 18”. This would allow me to store up to 8 Cabinet Master clamps on each end. I decided to use a center divider at around 8 3/8” to maximize the amount of space I had to use and provide stability. Now, the Height was the biggest pain…Like I said, I wanted to be tall enough to hang my 8, 48” Cabinet Masters on, but I didn’t want to make too tall that I couldn’t really use the top of the cart for my tool tote( I’m vertically challenged). So after some serious math and numerous adjustments, I came up with a 48” height on a base with 3” swivel casters. I just prayed that I was right…

I have an engineering background in Electronics…laying out printed circuit boards, component placement, and current. So I was very nervous and not at all confident with my ability to layout something this large and complex!

There was nothing left to do but do it. Grab my plywood and started cuttin…

After some new found stopped dado skills, I was able to get the top cut just the way I wanted it with the overhang for my Cabinet Masters…

Then, I had to figure out how to eliminate the waste material on the ends…I watched a ton of video on the net and decided this was the best way, a drill and jig saw…

Then attached the top..

I was really impressed at how easy this all turned out to be…I was sweating for nothing. I now had a serious confidence boost. I put the base together using a piece of ply 37” x 20” and 4 swivel castors..

Attached the base and tried my clamps….cross your fingers!

AHHHH the sweet smell of VICTORY!!!! Time for a beer!

I have much more to show, but this is getting pretty lengthy as it is and I have to get more photos in order. I will continue in a few days with the rest of the fixtures I put in to complete the cart…I am still working on how I want to finish it….any suggestions?

Thanks so much for all the help I have been given, in completing this project and thanks for reading!

-- Semper Fi, Randy Sr.

2 comments so far

View DavidH's profile


519 posts in 3710 days

#1 posted 10-31-2010 01:59 AM

looking good thanks for posting.

I normally don’t finish my shop projects other than a coat of varnish in some cases.

-- David - Houston, Texas. (

View NBeener's profile


4816 posts in 3141 days

#2 posted 10-31-2010 02:05 AM

I guess I missed it when ALL of these projects were posted.

Very cool !!!

Two things I learned:

1) A great way to screw up stopped dados, badly. If you need my method, just ask :-p

2) Whenever I put important stuff on the white board, at work, I take a picture of it, before I leave. We had the coolest couple that cleaned our office suite, but … in their enthusiasm … they were known to erase stuff, too !

Nice job. I like the multiple use idea, too !

-- -- Neil

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics